JP2566407B2 - Method of manufacturing cushions - Google Patents

Description

The present invention relates to a method of manufacturing a cover cushion for a chair having the effect of a carved pattern.

Traditionally, cushions for chairs have been handmade. The effect of the engraving pattern is obtained by arranging a cover cloth on a thin foam topping layer and a thick cushion, and sewing them with a decorative button or a thread at an appropriate position. The labor costs required for this are, of course, high and time-consuming.

Various attempts have been made to develop simple and economical automated methods of manufacturing cover cushions. Most of them use a vacuum mold, whereby the cover cloth is narrowed down to a desired mold. However, a vapor-impermeable elastomeric backing must be used to apply a vacuum to the fabric. However, when the cushioning product has a cloth backing, the cushion gives the skin a "hot" sensation. Because this impermeable backing doesn't do what breathing does. Such backing may be omitted if the fabric is tightly woven. However, dense fibers feel hot. Also, many modern cloths are not tightly woven. A typical example of an abnormal manufacturing method is Sanson et al., US Pat. No. 4,116,736, issued Sep. 26, 1978, “Method for manufacturing foam plastic cushion having peripheral frame and outer cover”.

In yet another alternative, attempts have been made to eliminate the heat sensation of vapor impermeable cover cushions by using heat in a combined mold to impart shape. For example, there is a cover cushion product obtained by preheating a cushion to be overlaid and then adhering it to a shaped cloth. One method of imparting shape to the cover cushion is to injection mold a foam material to obtain the cushion. However, when the cushion is injection molded, a skin is formed that gives a feeling of heat that is almost impermeable to vapor. The epidermis provides a generally stiffer feel when sitting, as well as a gentle and inflexible feel. Another option is to cut the cushion out of the foam block, which is time consuming and sometimes does not produce a cushion shaped to fit snugly on the shaped cover fabric. Sometimes. As a third method, a cushion that fits the shape of the cover cloth exactly,
Although there is a method of obtaining a cushion by injection-molding the inside of the cloth, a skin which gives heat is similarly generated.
In addition, the foam polymer soaks into the fabric and hardens the fabric fibers, resulting in a textured fabric. A typical example of such a method is August 1978.
Urai et al., US Patent No. 4,107,829, issued on 27th, can be cited as a method for manufacturing a seat cushion.

Furthermore, in order to obtain the desired shape, it is necessary to use elastically stretched fabrics, which are in most cases unfavorable in appearance and feel. .

In the present invention, the engraved cushion has a foam cushion and a cloth layer, and an air-permeable adhesive is adjoined to the cloth layer to adjoin the cloth layer to form a first shape mold and a second compression mold. It is compressed between the mold and heated steam is added to form a cushion with an engraved pattern. In the preferred embodiment, a skinless cushion is used to eliminate a vapor-free "heat-sensitive" layer between the cover and the cushion.
Moreover, the effect of giving a deep engraved pattern can be obtained.

The method of the present invention is illustrated in various examples. Broadly speaking,
Shaped mold (for example, reference numeral 12 from FIG. 1 to FIG. 4)
And 114 in FIGS. 9 and 11 and 15 in FIG. 22.
6) between which a foam cushion and an air permeable heat activated adhesive layer (eg 18
A cloth cover layer containing 1.5 to 8 g / ft ² of powder or spray, which melts at 5 to 210 ° F, is compressed to give about 230
Heated steam (eg steam) at a temperature high enough to provide a temperature of ˜240 ° F. is applied for about 2-35 seconds. The molded cushion is cooled for about 40 to 80 seconds.

That is, the above-mentioned assembly must be exposed to the above at a temperature and for a time such that the adhesive melts and is activated, and for such a length that the adhesive does not exude from the bonding line. . The cooling must be sufficient for the adhesive to set. These factors are
It changes depending on the target shape and the material of the shape mold. Further, the above-mentioned method may have an additional step if desired, and the heating steam is preliminarily changed from 2 seconds.
The cover fabric may be exposed for 10 seconds to form the shape in the forming die.

First embodiment, single-step method In the single-step method of the first embodiment, a press 10 (Figs. 1 to 4) has a lower die 12, and this lower die 12 has a shape of the top of the cover cushion, that is, the side of the cover, and further has a ridge 14 (first
(FIG. 2, FIG. 3 and FIG. 3) has an effect of giving an engraving pattern. The press 10 also has an upper mold 16 having a generatrix shape on the back or cover side of the chair cushion. As shown in FIG. 1a, one cover cloth 18 is laid on the lower mold. The cushion means comprises a topping layer 20 of skin cushioning foam cushion material and a thick skinless cushion 22. The topping layer 20 is such that an air permeable heat sensitive adhesive is applied to both sides thereof and then placed over the fabric 18 of the lower mold 12. Next, after the air permeable heat-sensitive adhesive is applied to the back side of the cushion 22, the lower mold 12
Place the cushion 22 within the recessed portion 24 of the. Finally,
A backing cloth 26 is placed over the thick cushion 22. After being laminated as described above, the upper mold 16 is pressed against the lower mold 28 to form the cavity 28 (FIGS. 2 and 2a). The total thickness of the laminate, i.e., the total thickness of the cover cloth 18, the cushion 22, and the topping layer 20, is thicker than the distance between the upper and lower molds 16 and 12 within the cavity 28, When the upper mold 16 is pressed against the lower mold 12, the thick cushion 20 and the topping layer 22 are compressed so that the cloth layer 18 has the shape of the lower mold 12. become.

Also, the cushions 20 and 22 are compressed so that they have the shape of the cavity 28. After pressing the molds against each other, heated steam is injected into the cavity 28 so that both the cloth and the cushion take the shape of the cavity, solidifying the heat sensitive adhesive to form the following laminate: Adhere to each other.
The result is a cover that is effective in providing a deep engraving, but is air permeable and does not give the feeling of heat that polymer backings or cover cushions with a vapor impermeable skin layer. Cushions are provided.

The press 10 has a frame 30 that supports the lower mold 12 above the floor and supports the upper mold 16 above the lower mold 12 (FIG. 1). A hydraulic cylinder 32 is connected to the upper mold 16 so that the upper mold 16 moves closer to the lower mold. The hydraulic cylinder 32 is supported on the top of the frame 30.

The lower mold 12 (FIGS. 1 and 3) has an epoxy resin mold surface and substantially has the outer shape of the cover cushion manufactured by this apparatus, that is, the shape of the cover surface. The product (unshaped) of the cushion 36 is as shown in FIG. In the manufacture of this cover cushion 36, the lower mold surface 34 has a ridge 14 near the confluence of the seat portion 37 and the back portion 36, which results in the cushion 36.
Two dents 42 are formed on the top. The ridges 14 are only typical of the details that can be dented in the cover cushion product. Other types of shapes include those that include a generally convex surface at the center of the sheet portion 37 of the lower die 12. From this shape, a central portion on the generally concave surface of the cushion 40 is formed. The seat portion 38 of such a cushion is adapted to fit the back of the human body at its central portion. Back of lower mold 12 39
The convex shape provided at the center of the cushion creates a similar indentation on the back of the cushion. The lower mold surface 34 has a deep rounded edge portion 44, which completely surrounds the lower mold surface 34 and provides a deep plush appearance for the cover cushion. To form the rounded side of the deep draw of the cover cushion 36.

The mold surface 34 further includes an apron 46 along the periphery of the edge portion 44, and when the upper die is moved to the lower die side on the edge portion 4 as described below. The retainer ring 68 is designed to be pressed. An aluminum steam chamber 48 is arranged just below the lower mold surface 34 (FIG. 1). The steam chamber 48 substantially matches the shape of the rear surface of the lower mold surface 34, passes through the wall of the steam chamber 48 to reach the lower mold surface 34, and further has a plurality of openings passing through this surface 34.
50 are provided.

When the molds are pressed together as shown in FIGS. 2 and 2a, steam is injected into the steam chamber 48 and then formed between the lower mold and the upper mold. It is jetted through the opening 50 into the existing cavity 28. Although not essential, it is preferable to provide this steam chamber 48 to minimize the mass that must be heated when injected into the cavity 38. This can reduce possible condensation in the lower mold as well as in the cavity 28. This is because the amount of steam heat that heats the machine is small.

A plurality of electric resistance heaters 52 are provided along the lower wall of the steam chamber 48 in order to mitigate the condensation of steam and the decrease in steam temperature, and can simultaneously heat the steam chamber and the lower mold surface 34. it can. Preferably, heater 52 heats steam chamber 48 to a temperature of about 170 to 200 ° F. As a result, the lower mold surface 34 is also heated, and the problem of condensation occurring during steam injection is alleviated. As discussed below, lower temperatures can be used when using aluminum molds.

The lower mold 12 is further provided with a support housing 54 that supports the lower mold surface 34 and the steam chamber on the frame 30. The size and shape of the support housing 54 is not important here.

The upper mold 16 has an upper mold surface 56 having an epoxy resin step 58 and an apron 60 (FIGS. 2 and 2a).
Is to have. The step portion 58 enters the lower mold surface 34 to compress the cloth 18 and the cushions 20 and 22, and the lower mold surface 34
The shape of is given to these. The upper mold surface 56 further has two grooves 57 located above the ridge 14 on the lower mold surface 34.

The upper mold surface 56 includes a plurality of openings 56 for injecting cooling air into the cavity 28 and creating a vacuum therein. This will be described later. Above the upper mold surface 56, the lower mold housing 64 carries the former. A lower die 56 is formed within the housing 64.

A retainer ring 68 (FIGS. 1-2a and 4) is provided around the apron portion 60 of the upper mold 16.
The retainer ring 68 is composed of a plurality of ring elements 70,
Each of these is held by a piston 72 of a hydraulic cylinder 74 supported from the side of the upper mold housing 34. As shown in FIGS. 2 and 2a, when the upper mold 16 is lowered right above the lower mold 12, the cylinder 74 moves the retainer ring 68 to the apron portion 46 of the lower mold 12. And press it. As shown in FIGS. 2, 2a and 3, the lower mold apron portion 46.
Has a larger lateral dimension than the apron portion 60 of the upper mold. Furthermore, when the two molds are put together, the two apron parts do not come into direct contact with each other. When the two molds come together, there is direct contact between the upper mold and the lower mold only via the retainer ring 68, as shown in FIG. Since the cloth 18 and the topping layer 20 are large enough to overlie the apron 46 of the lower mold in the state of being stacked on the lower mold (1a
The retainer ring 68 compresses the topping layer 20 and the cloth 18 against the lower mold apron 46 when the two molds are pressed together.

The molds are put together and the step 58 of the upper mold 16 is replaced by the lower mold surface 34.
When pressed against the step portion 58, the step portion 58 attaches the cushion 22 and the topping cushion 20 to the seat portion 37 and the back portion of the lower mold.
Compress against 39 and. Cushions 22, 20 and cover cloth 18
As described above, since the total thickness of and is larger than the distance between the molds within the cavity 28, the cloth 18
Is pressed against the part and pushed in. The compression of the cushions 20 and 22 presses the fabric 18 and the topping layer 20 against the lower mold sheet and back, so that the topping layer 20 and fabric overlaid on the apron portion 46.
These parts of 18 are squeezed inward of the lower mold. Without the retainer ring 68, the fabric 18 and the topping layer 20 overlying the apron portion 64 would likewise be rapidly squeezed, resulting in wrinkling of the product when the molds were quickly pressed together. . This wrinkle forms a narrow area 34 near the corners of the product cushion and between its seat and back.
Remarkable. To prevent the fabric from being rapidly squeezed in this manner, downward pressure is applied to the apron portion 46 of the lower mold 12 via the retainer ring 68 and into the cavity 28 when the cushion is compressed. Cloth with controlled speed 18
And the topping layer 20 is narrowed down slowly. It has been discovered that uniform pressure is less preferred. Therefore, the retainer ring is inserted through the cylinder 74.
Where appropriate pressure can be applied to the various ring elements 70 of 68, where higher slip under control is desired, higher slide under control is desired. By the way, I try to apply low pressure. Each cylinder 74 is individually controllable and can thus be adapted to provide the desired pressure to each ring element 70. The exact pressure required between the ring element 70 and the apron portion 46 is unknown, but must be determined experimentally for a variety of different cover fabric shapes. The important thing is the ring element
It must be ensured that none of the 71 holds the cover cloth or topping layer firmly into the apron portion 46 and prevents it from slipping into the cavity 28. Some slippage is required to prevent wrinkling, however, high pressure is applied to the corners of the mold to reduce wrinkling that would occur without the ring element. Cloth 18 and topping layer 20 as described above.
Are first placed on the lower die 12 so as to overlap each other. Cushion 22
Place it in the lower mold and place a backing 23 on this cushion 22.
To place. The cloth 18, the toppings 20 and the backing 23 have almost the same area and must be cut to a size that covers the edge of the apron portion 46 of the lower mold 12 (Fig. 1a). Cloth 18, topping layer 20 and backing 23
Both are cut into a substantially rectangular shape. The corners of the cloth 18, topping layer 20 and backing 23 are covered by the cover cushion 36
Make a radial notch 76 at the corner of (Fig. 14). The radial cuts 76 have the effect of reducing wrinkling of the fabric as it is squeezed into the cavity 28. The fabric 18, topping layer 20 and backing 23 make a plurality of lateral cuts along the portion of the fabric 18 and topping layer 20 where the narrow portion 43 is formed. This can significantly reduce the wrinkles in the narrow area. The radial cuts 76 and the lateral cuts 78 form a material flap between the cuts. Thus, the flaps are squeezed underneath the ring element 70 at this speed, and there is little effect of adjacent flaps on the fabric section.

It has considerable latitude in choosing the type of fabric 18 to be used. On the other hand, some conventional methods required the use of stretched fabrics, but with this method non-stretched fabrics can also be used. In the case of non-stretch cloth, the elongation is about 3 to 5%. It's a very finely woven cloth that looks good to you. Furthermore, the cloth may or may not be backed. There are very few unusable fabrics, even those that are fairly complex in shape.

Before placing the topping layer 20 on the fabric 18 on the lower mold 12, an air permeable adhesive needs to be applied to both sides of the layer 20. The adhesive is preferably a powdered, heat activated thermoplastic adhesive with a particle size on the order of 80 to 700 microns.
Nylon and polyester are examples of heat melting types that can be used. Preferably the particle size is 500 to 800 microns. The melting point of a thermoplastic adhesive is approximately 185 to 215 ° F.
Should be about. It has been found that one with a melting point of 205 ° F is very good. Furthermore, the adhesive is a topping layer
Use on both sides of about 20 to 2.5-8g per square foot on one side. Preferably, the range of use of the adhesive is
2.5 to 3.5 g per square foot, with 3 g per square foot being most preferred. Above 8 grams per square foot, the adhesive begins to form a hard film, which adversely affects the feel of the cushioned product. Below 2.5g per square foot,
The use of powdered adhesive seems to result in insufficient adhesive between layers, making it impossible to form engraved patterns such as grooves.

Alternatively, if spraying is performed in an open pattern, it is possible to apply the adhesive by heating and melting spraying. The material is preferably sprayed in a web-like open pattern. A highly preferred method is to use urethane with an initial melting point of about 190 ° F. However, this melting point rises little by little as it melts. This facilitates application at low temperatures and provides resistance to thermal degradation after heating. An important effect of using this predominant adhesive over powder is that the adhesive does not escape from the bond line. If it is granular, it may fall into the holes of the cushion foam. Also, less adhesive, less than about 1.5g per foot on one side, is sufficient. Urethane is softer than the above-mentioned nylon and polyester.

Still other adhesives may be used instead of the above. For example, solvent sprayed thermoplastic adhesives. Such material is usually urethane. This can be sprayed almost in the same manner as the above-mentioned heat-melting spray and gives the same effect. The topping layer 20 is a polyurethane foam having a density of 30 HR (high resistance). The pore size of the polyurethane should be related to the particle size of the adhesive and the use of the adhesive should prevent these particles from penetrating deep into the pores. This is because it is desirable that most of the adhesive be retained on the surface of the topping layer and extend to the topping layer at a distance.
Thick cushion 22 is a foam polyurethane without skin. However, the density is higher than that of the topping layer 20. It preferably has a density of about 50 HR. The epidermis can be easily avoided by using cut foam rather than a shaped bundle.

The thick cushion 22 should be located directly above the topping cushion 20, and should be within the apron portion 46, as shown in Figure 1a. Alternatively, the material is cut in advance (FIG. 12), its corners are rounded, and the material for the narrow portion 43 of the product cushion is removed. Further, the groove 80 may be provided on the bottom surface of the cushion 22. The groove 80 is aligned with the ridge 14 of the lower mold 12 and causes the ridge 14 to push the topping layer into the groove 80 when the molds are pressed together. The provision of the groove 80 on the cushion 22 allows the formation of a well-defined clear dent 42. However, this groove 80 is optional as described above. The cushion 22 can be a single piece of constant density polyurethane foam (Figure 1a). Cushion 22 at will
Can also use multiple cushioning elements with different densities (FIGS. 13 and 21). For example, the low density foam layer 82 may extend across the entire cushion 22 (FIG. 13). The high-density cushion 84 may be arranged below the portion of the cushion 22 arranged within the seat of the chair. High density cushion 84 recess
Within 86, another foam pad 88 of even higher density may be placed to provide a strong support underneath the seat that requires support. However, the portion of the cushion 22 that is the back of the chair may be provided with another low density cushion 90. The cushion 90 is provided against the foam layer 82, which rests against the cushion 84, to provide the desired chair back softness.
The composite cushion shown in FIG. 13 is integrally shaped before placement in the mold. Conventionally used adhesives can be used to bond the various cushioning elements. Whatever adhesive is used, it must be air permeable so that it does not feel the thickness of the non-air permeable cover cushion. Furthermore, the adhesive must be able to withstand the temperatures of the manufacturing process. Incorrect use of the adhesive will result in the formation of a somewhat impermeable layer, which may result in abnormally poor permeability. As described above, the cushion 22 may be adjusted with or without the use of the composite cushion 22 shown in FIGS. 13 and 14, or with the constant cushion 22 of FIG. 1a. So that it fits within the lower mold surface and does not extend outside the apron portion 46 (FIGS. 1a and 2a).
Figure). Before the foam cushion 22 is placed on the topping layer 20, a granular thermoplastic adhesive is applied to its back surface 23 (first
Apply on top. After stacking the foam cushion 22 on the mold 12 and the topping layer 20, the backing 26 is a cushion.
It is arranged on the adhesive application surface 23 of 22. The backing 26 has approximately the same area as the cover fabric 18 and the topping layer 20 and extends over the apron portion 46 as shown in FIGS. 1a and 2a. The backing 26 may be constructed of a vapor permeable cloth. Nonwovens made of polyester have been found to be effective.

As mentioned above, the cushion elements 18, 20, 22 and 26
Is placed on the lower die 12, and then the upper die 16 is lowered by the hydraulic cylinder 32 on the lower die 12. The upper mold 16 is
It is held at a controlled distance from the lower mold so that the cloth and topping layer 16 is not pinched between the upper mold surface 52 and the lower mold piece. An adjustable stopper may be provided to ensure the above holding. Immediately after the two molds have been brought to a controlled distance, the cylinders 74 operate at their own set pressures and the ring element 70 is lowered and overlaid on the lower mold apron portion 46. Engages the backing 26, the topping layer 20 and the fabric 18, and the topping 20 layer and the fabric
Controls the extent to which 18 slides into cavity 28. After the ring element 70 is engaged in the above manner, steam is injected into the preheated steam chamber 48, and the steam is then introduced through the opening 50 into the cavity 28 formed between the two molds. .

Steam temperature is very important. That is, it is important that the steam temperature melts and activates the thermoplastic adhesive layer, and as described above, is about 185 to 2
It shall have a melting point of 10 ° F. It is also important that the vapor does not condense on the mold surface and in the manufactured cover cushion. Damp cushions are heavy to handle and difficult to wear on chairs. Therefore, it is preferable to use dry superheated steam. The temperature of the steam injected into the cavity 28 is approximately 230 to 240 °
F, this temperature can be measured by a heat sensitive piece whose color changes in a certain relatively narrow temperature range. This heat-sensitive piece is provided in the cushion assembly arranged on the mold, and is removed after the cushion manufacturing process to grasp the temperature in the cushion. It is effective that the steam temperature immediately before injection into the steam chamber 48 is 700 ° F.

Usually steam is injected for only 20 to 30 seconds, preferably 25 seconds. In contrast to the above epoxy tools, shorter times are required for aluminum tools, ie 2 to 5 seconds. If spraying is carried out for a long time, the melted adhesive will soak into the cushion and a strong adhesive layer will not be formed, making it difficult to hold the cushion aggregate pair together. When you inject steam,
The adhesive on both sides of the topping layer 20 should be covered with the topping layer 20.
Adhere to 18 and cushion 22. The adhesive on the back of the cushion 22 adheres it to the backing 26. Finally, the adhesive on the apron portion 46 and on the upper portion of the topping layer 20 adheres the topping layer 20 to the cloth on the apron portion 46, as well as the backing overlaid on the apron portion 46. To glue. The heated steam is important beyond melting the adhesive. That is, it has a role of forming the cover cloth 18 into the shape of the lower mold surface. Further topping layer 20
It also serves to permanently make the cushion 22 substantially in the same shape as the cavity 28. In other words, the vapor has the effect of shaping the topping layer 20 and cushion 22 and forming a composite density foam core within the product cover cushion 36. As mentioned above, the foam core
The vapor "densifies" the foam because it is compressed in the cavity 28 when the molds are mated.

It is the hepatorenal that spreads the adhesive sparsely. By doing so, when melted by steam, it becomes a discontinuous adhesive layer, and when the cushion cools down and is mounted on a chair and the adhesive solidifies, the steam can flow through the cushion and the adhesive layer.

After injecting steam for 20 to 35 seconds, the steam is stopped, a negative pressure is applied to the steam chamber, and cooling air is injected into the chamber of the upper mold 16. Cooling air is forced through the openings 62 into the cavity 28 to cool the cushion and "solidify" the molten adhesive particles and "solidify" the foam core in its shape and compactness. . Unpressurized introduced cooling air lasts approximately 40 to 80 seconds. This is because it has been found that the cover cushion is sufficiently cooled. After that, the completed part is removed from the mold and mounted on the chair by the method described below. After the molded cover cushion 36 has been removed from the mold, excess cloth and topping layers and backing are cut from the cushion along the dotted line 90 (Figures 14-16), but with the narrow width of the flange 92. Leave the web. Because this material is used to secure the cover cushion 36 to the chair (first
17 is the meaning 19). The chair frame 94 (Fig. 17) to which the cover cushion is attached is the inner frame 96 and the outer frame 98.
It consists of and. After the cover cushion 36 has been trimmed cut, the excess web 92 is folded back along the back cushion into the gap between the inner and outer skeletons.
Inserted along the edges of these frameworks. Both frameworks are
The fastening means, such as fasteners 102, are then pressed together, thus sandwiching web 92 between the two frames. The inner frame 96 supports the cover cushion and the outer frame sandwiches the cushion web between the inner and outer frames (Fig. 19).

When the web 92 is folded back on the back of the cushion 36 (No.
(Fig. 19), in the portion folded back around the corner 41 and the narrow portion 43, folds or the like tend to occur in the exposed portion of the cover cushion without being sandwiched between the two frames. In order to remove such folds, in the above molding process,
The web 92 is provided with a series of parallel indentations (Fig. 14,
(Figures 15, 16 and 16a). The apron portion 46 of the lower mold 12 is provided with a plurality of projections 106 (FIGS. 3 and 4) at intervals, and a corner 41 and a narrow portion 43 are formed adjacent to the projections 106. Has been done. Each protrusion 106 is rounded and has a length longer than its width. The vertical axis of each protrusion 106 is oriented substantially parallel to the direction of movement of the fabric below the retainer ring 68.

Corresponding sets of small recesses 108 are provided on the apron 60 portion of the upper mold. When the two molds are brought together during the cushion molding, the recess 108 is positioned right above the protrusion 106. However, the protrusion 106 has a recess 1
It doesn't fit exactly in 08. As mentioned above, when the upper mold compresses the cushion, causing the cloth and cushion to assume the shape of the lower mold, the cloth is apron part.
It is necessary to be able to slide between 46 and 60. Therefore, there is always a gap between each protrusion and recess to allow the fabric to slide between them. In addition, the orientation of the elongated recesses, as well as the elongated protrusions parallel to the direction of movement of the fabric into the mold, prevents them from being caught by the protrusions 106 or the recesses 108 and at a speed controlled by the ring element 70. It can be slid into the cavity 28.

A vapor hole 110 is provided between each of the protrusions 106. The steam hole 110 is communicated with the steam chamber 48, and the steam is discharged from the steam chamber 48.
When introduced into the steam, the steam passes through the steam holes 110 and permanently forms a depression 104 in the web 92 of the cover cushion 36.

The indentation 104 causes a groove to be formed between adjacent ridges on the web 92 (Fig. 16a), leaving the curved portion of the web 92 (around corner 41 and near narrow portion 43) folded over behind the cushion. It is possible to put together different materials (Fig. 18 and
(Fig. 19). Excess material that collects when the curved portions of the web 92 are folded back backwards collects in the indentations 104. The ridges adjacent each indentation 104 are in close proximity to one another and the material is folded into the indentations and brought together. the important thing is,
Controlling the packing of the material to prevent it from entering the exposed portion of the cover cushion 36 that is not sandwiched between the two frameworks.

Thus, the piece of material does not please in the visible portion of the cushion attached to the chair.

In the methods described above, the shape of the completed cushion cannot accurately take the shape of the lower mold. Therefore, in order to have a very deep or sharp engraving effect, it is necessary to take an exaggerated shape on the lower die surface. That is, the engraving effect (eg, ridge 14) of the lower mold surface should be more prominent than the depth or shape of the engraving effect (eg, groove 42) of the product cushion. The engraving effect that imparts depth and sharpness is preferably performed in a two step process.

Second Example, Two-Step Method A second two-step method of making a chair cover cushion in accordance with the present disclosure is illustrated in FIGS. 15-11. The first step is to pre-form the cover cloth on the cover cloth body having a shape. The second step is similar to the one-step process described above.

The modified device 112 has two upper molds and a lower mold below and movable between them.
The lower die 114 is similar to the lower die 12 described above, except that the former is placed on a portable means such as the wheel 116, where the die 114 is on the upper side. Track 118 from below one of the molds to the position below the other upper mold
Can be moved over. The first upper mold 120 is equivalent to the upper mold 16 described above, and the difference is that the upper mold surface has a different shape (FIG. 7). The difference in shape is illustrated in FIG. 9, where the molds 114, 120 are
They are shown close together. First upper mold 12
The zero die surface 122 closely matches the shape of the lower die surface 34 of the die 114. The first upper mold surface 122 and the side mold surface 34 can form a cavity 124 having a size that accommodates only the cloth 18 and the topping layer 20 between them, and when the mold is closed. The topping layer 20 is compressed.

The second mold 126 has a mold surface 128 having the same shape as the upper mold surface 56 described above. When the lower mold 114 moves under the upper mold and the two molds are pressed against each other, a cavity having the same shape as the cavity 28 is formed, in which the cloth 18 having the shape and the topping 20 are thick. The foam cushion 22 can be accommodated.

The press 112 operates as follows. First, eighth
As shown in the figure, the fabric 18 is placed on the lower mold 12. One of the thermoplastic adhesives described above is applied to one side of the topping layer 20 and overlaid on the adhesive coated cloth 18. The lower die 11 is moved to a position below the first upper die 120. The upper mold 120 is then lowered onto the lower mold 114 at a controlled distance as described above, causing the fabric to be squeezed into the cavity 124. Immediately after the two molds are brought together, the retainer ring element 70 is pressed by the hydraulic cylinder 74 against the apron portion 130 of the lower mold 114. As mentioned above, this is the cavity
Controls the rate of cloth sliding into 124.

Next, dry superheated steam is injected into the steam chamber 48 (FIG. 9) of the lower mold 114. The steam then ejects through the openings 50 into the cavities 124 to impart a shape to the fabric 18 and topping layer 20 and the fabric and topping layer foam into a shell similar in shape to the cavities 124. And topping layer foam. Steam should be about 5 to 10 seconds. As noted above, less time (2 to 5 seconds) is used when aluminum dies are used. The steam is then cut off and a negative pressure is introduced through the bottom mold, introducing air through the openings in the upper mold 122. The negative pressure acts for about 15 to 20 seconds. It has been found that this time is sufficient to cool the above parts. The low steam, vacuum, and temperature are the first of the two-step process.
This is because at the stage there is no thick cushion and it is not necessary to heat it. Thereafter, the upper mold 120 is raised to the retracted position shown in FIG. The cover fabric 18 and topping layer 20 are thereby molded to give the final shape or a shape similar thereto. They retain their shape even if removed from the lower mold at this point. As shown in FIG. 11, the lower mold 114 is provided with a second upper mold 126 by a screw drive or the like (not shown).
Rolled on wheels 116 that straddle rails 118 below. When the lower mold 114 moves from under the first mold 120 to the second upper mold 126, the cover cloth body 134 is given a shape.
(Molding cloth 18 and topping layer 20) are left on the lower mold 114. The thick foam cushion 22 is coated on both sides with a particulate or other heat-activatable adhesive as described above and placed in a shaped cover cloth body 134. Similarly, the cushion 22 has the shape shown in FIG. 12, with its corners rounded and the material cut to form a constricted portion 43 in the product cushion. The groove 80 can be curved. Cushion 22 can be a single foam block 22 as shown in FIG. 11 or a thirteenth foam block 22.
It is also possible to have a composite foam structure with multiple density layers, as shown.

Once the cushion 22 has been given a shape, the cover cloth body
Lower mold 114, which is located within 134 and is shown in FIG.
When prevented from spreading over the apron portion 130 of, the cloth backing 26 is placed on the cushion 22 and the lower mold 113
It is made to spread to the surrounding apron part 130.

The hydraulic cylinder 136 replaces the second upper mold 126 with the lower mold 126.
And hold the upper mold 126 at the above-mentioned “control distance”, whereby the cloth and topping layer are placed in the cavity 28 formed between the second upper mold 126 and the lower mold 114. Narrow down to. However, in this first stage, the final shape is not set. Similarly, a retainer ring 68 (FIG. 11) composed of a plurality of ring elements 70.
Are lowered into the apron portion 130 of the mold 114 and control the rate of slipping of the fabric into the cavity 28.

Dry superheated steam is introduced into the steam chamber 48 through the opening 50 and then injected into the cavity 28 between the two molds for about 20 to 25 seconds, preferably 20 seconds. This melts the adhesive on both sides of the cushion 22,
22 to the topping layer 20 as well as the backing layer 26,
The cover cushion 36 shown in FIG. 14 is formed. The cover cushion 36 is configured as having the composite laminated foam cushion 22 shown in FIG. 21 or the constant density foam cushion 22 shown in FIG. Then, a negative pressure is applied to the cavity 28 for about 60 to 75 seconds to cool these molded products. As shown in FIGS. 6 and 11, the track 118 extends across the platform 140 along the underside of the two upper molds 120,126. Stop 142,14
2'is provided at the end of the track 118 and the lower mold 114
It serves as a positioning means of. When the lower mold 114 comes into contact with the stop 142 '(FIG. 11), the lower mold 114 is in a position where it can match the upper mold 126.

In the first stage, the cloth and the topping layer are co-molded, and the second
In the step, the cover cushion is molded twice by the two-step molding method in which they are formed on the same lower mold together with the thick foam cushion, and is narrowed down in a state very close to the shape of the lower mold surface. . In particular, the one-step molding method cannot produce a deep engraved pattern on the cushion, but the two-step molding method is successful.

Third Example, Two-Step Method The method of the third example is in a sense a second version of the two-step molding method described above. Modifications and improvements described with respect to the two-step method are equally applicable to the one-step method of the first embodiment.

Press 150 used in the method of the third embodiment of the present invention
Are illustrated in Figures 11-32. Press 150
Is similar in structure and operation to the correction press 112 shown in FIG. The press 150 includes two upper molds 152 and 154 and a movable lower mold 156. Upper mold 152 extends into lower mold 156 and is substantially the same as first upper mold 120 so long as it forms a shell-like member similar to that formed by the method steps illustrated in FIG. The shape. However, the mold 152 is
Including 58, this mold surface 160 is made of aluminum,
Not made of epoxy. The mold surface 160 forms one wall of the steam chamber 158. The steam chamber 158 is provided with a plurality of electrical resistance heater elements 162 that heat the chamber itself and the mold surface 160. The steam is jetted into the steam chamber 158 by the three nozzles 164 that have been contracted at intervals (Fig. 22).
Inside the steam chamber 158, it extends over the entire width of the mold 152. Each nozzle 16 is basically a tubular element, with a plurality of openings interspersed along its length more or less uniformly on its surface. Since the three nozzles 164 are arranged in the steam chamber 158 at intervals, the steam is uniformly distributed in the steam chamber 158, and the surface is randomly distributed on the mold surface 160.
It is injected uniformly through an aperture 166 having a diameter of about 0.060 inches.

The upper mold 150 further includes a locating pin 168 extending downwardly therefrom. Each positioning pin 168 has an upper mold 152
Are mounted on mounting blocks 170 mounted at the corners of the. Each positioning pin 168 is adapted to be introduced into the opening 244 (FIG. 24) of the guide block 245 arranged at the corner of the lower mold 156 when the molds are pressed against each other. An adjustable spacer stop 168a (FIG. 22) on the mounting block 170 maintains the correct spacing between the molds when the mold 150 is lowered.

The lower mold 156 has substantially the same shape as the lower mold 114 shown in FIG. The shape of that surface is almost the same as the mold surface 34 of the lower mold 12. However, the lower mold surface 172 is made of aluminum and is not made of epoxy, but the lower mold 156.
It serves as the wall of the steam chamber 174 provided inside. Steam room 174
Is similarly provided with three steam injector nozzles 164 similar to the above-mentioned nozzles, which allows the steam to be uniformly injected into the steam chamber 174, and at the same time, lower steam It is designed to be ejected from openings randomly distributed on the surface of the mold surface 172. The vapor chamber 174 is also heated by the resistive element 162 which heats the vapor chamber and the die surface 172 to prevent vapor condensation and to prevent the portion formed by the die from getting wet.

The mold 156 includes a plurality of clamps 178 spaced on three sides of the lower mold 178. Further structure is clamp 1
Another set of clamps 180, similar to the 78, is the fourth of the lower mold 156,
, Are arranged along the front side. These clamps form the clamp ring on the aforementioned segment.

Each clamp 178 (Figure 26) has two spaced mounting brackets mounted on the vertical sidewall of the lower mold.
182, 182 ', with a bell crank 184 disposed therebetween. One arm of the bell crank 184 includes a tubular sleeve 186 that traverses and extends through the bell crank 184 with which the openings 19 in the brackets 182, 182 'can be made.
Mounting bolt 18 that penetrates 0,190 'and sleeve 186
The bell crank 184 is pivotally mounted between the mounting brackets 182, 182 '. The other arm of the bell crank 184 contains a clamp bar 190 that traverses the bell crank 184. Additionally, the third arm of bell crank 184 has an opening 192 therethrough. Pin 194 is clevis bracket 198
The clevis bracket 198 is fixed to the third arm of the bell crank 184 through an opening 196 and an opening 192 passing through the free ends of the clevis bracket 184. In addition, the third arm of the bell crank is provided with a handle 198 used to manually operate the clamp.

The pneumatic cylinder 200 is suspended between the two mounting brackets 182, 182 '. Bolts 202, 202 'pass through the openings 204 of the brackets 182, 182' and are inserted into the screw holes 206, 206 'on one side of the cap member on the block forming the top of the cylinder 200. One end is attached to the piston in the cylinder and the other end is the clevis bracket 197.
A piston rod 210, which is fixed to the cap by a screw, penetrates the top of the cap member 208.

The cylinder 200 is a return type. The pneumatic pipe 212 is connected to this, and the piston rod 210 is
It is designed to be extruded from (Fig. 26).

When air is jetted from the pneumatic pipe 214 to the distribution block screwed to the cap member 208, the piston rod 210 becomes
It is designed to pull in. When the bell crank 184 pivots on the mounting belt 188 to a clamp position when the piston rod 210 is fully extended, the clamp member 208 causes the clamp member 208 to a closed clamped position relative to the apron portion 218 of the lower mold 156. Take (Figure 23 and Figure 24). Piston rod 21
When the 0 is retracted into the cylinder 200, the clamp 178
Take the unclamped position as shown in FIGS. 22 and 26.

When in the clamped position, the clamp 178 will embrace the cloth between the clamp bar 190 and the apron portion 218. In the clamped position, the cloth is bar 190 and apron section 218.
It does not prevent sliding between and, but rather allows for limited sliding between them.

The extension clamp assembly is mounted on all of the lower mold 156 (157, FIGS. 24 and 25a to 25c).
The elongate clamp assembly 220 has an elongated angled support 222 having a horizontal web 224 and a vertical web 226. The horizontal web 224 has a recess 228 along the leading edge of the lower mold 156.
It is slidably disposed within (FIGS. 23 and 25a to 25c). The vertical web 226 provides a full vertical surface 159 for the lower mold 156 when the elongate clamp assembly is not operating.
(Fig. 25a). Mounted on the vertical web 226 are three clamps 180, which are
Except that it does not have a clamp bar 190
Similar to clamp 178. Instead, the clamp 180 has a grooved clamp member 230 mounted on the bell crank 184. The clamp member 230 merges with the channel-shaped member 232 mounted on the horizontal web 224 when the clamp 180 is clamped (FIGS. 23, 25b and 25c).
Figure).

The clamp 180 is movable in series with respect to the front surface 159. This is because these three pieces are mounted on the angle support 222 which can be pulled out from the front edge of the lower mold 156 (FIGS. 25a to 25c). A double acting pneumatic cylinder 234 is mounted on the vertical web. The pneumatic cylinder 234 is fixed to the vertical web 226, and the piston 23 of the pneumatic cylinder 234 is fixed.
6 is fixed to the vertical front surface of the lower mold 156, and the vertical web 22
It penetrates 6 (Figs. 25a to 25c). Cylinder 234
Is operated and the piston 236 extends from the cylinder, the angle support 222 is separated from the lower mold 156 (FIG. 25c). Air cylinder 234 is working, piston
When 236 is retracted, the support 222 is pulled toward the lower mold 156 (FIGS. 25a and 25b).

In order to guide the angle support 222 from the extended position to the retracted position, a pair of guide three parts 238 are provided on the vertical web
Spaced from each other on 26 '. Lower mold
A guide rod 240 fixed to the vertical front surface 159 of the 156 is slidably received in the guide three portion 238.
The guide sleeve 238 slides along the fixed guide rod 240 as the extension clamp assembly 220 extends and retracts. Since the two guide rods 240 are parallel,
They control the movement of the elongate clamp assembly relative to the lower mold and mitigate rattling as well as irregular movement of the elongate clamp assembly.

Each clamp 178, 180 is automatically and independently operated by the controller 181 (Fig. 23). In operation, the clamps 178, 180 simultaneously open and close the clamps, however, it is desirable for each clamp 178, 180 to exert its own selected clamping pressure on the edge of the fabric. The clamping pressure will be dependent on the wrinkles that may occur on the fabric as it is formed. It is usually desirable to increase the clamping pressure if there are significant wrinkles, however, this pressure usually prevents the cloth from slipping between the clamp and the apron portion of the lower mold. It does not hinder.

If the cover part is manufactured almost symmetrically,
The clamping pressure by the clamps 178, 180 should be symmetrical as well. For example, the sides 155,155 ′ of the lower mold 156
Each clamp 178 attached to one of (Fig. 24)
A clamp pressure equal to that of clamp 178 mounted on the other side must be applied. The clamps 180 and 157 of the lower mold 156 have the same clamping pressure as that of the clamp 178.
It must be applied directly on one end 157 'of the mold 15. The clamps 178 and 180 are arranged symmetrically with respect to the edge of the lower mold 156. Five clamps 178 are arranged along sides 155 and 155 'which are directly opposite to each other via the mold. The three clamps 180 are mounted so as to directly face the three clamps 178 at one end 157 '.

The upper die 154 has substantially the same shape as the upper die 16 described above. The upper mold 154, however, is of additional construction. First, it has a steam chamber 242, which is of the same construction as steam chambers 158,174. Secondly, the upper mold 154 has positioning pins 168 at its four corners, and when the lower mold 156 is moved under the mold 154 and pressed against each other, It is designed to be received by the positioning pin hole. Thirdly, the groove 24 that makes an apparent turn along the periphery of the step 248 of the upper mold 154.
6 (FIGS. 22 and 23) are provided. The purpose of this groove 246 will be explained below.

Having described the apparatus used in the third method, the method is described in detail below. First, extension clamp assembly 220 has been retracted to the position shown in Figure 25a, with all clamps 178, 180 released (Figure 22). Lower mold 156
The cloth 250 is overlaid. This cloth 250 is spread over the apron portion 218 along the lower mold and overlaid on the horizontal web 224 (FIG. 14). A small piece of hinge cloth 250a is overlaid on the cover cloth 250 at the juncture of the seat and back (No. 29).
(Shown hidden in figure). This reinforces the cover cloth 250 at its joints and provides cushioning as well as cover assembly.
When the 288 is handled, it prevents the folds from forming when the whole is folded forward. The cloth 250 is a woven cloth (woven cloth, non-woven cloth) with open eyes, and has the above-mentioned adhesive on the upper surface (that is, the surface facing the upper mold 152 when the cloth is placed on the lower mold 156). One of is applied.

Clamp 1 after the fabric is in place on the lower mold 156
78,180 will clamp (Figs. 24 and 25b). The elongate clamp assembly 220 is then actuated to withdraw from the lower mold 156 and stretch the fabric (Figure 25c). The clamping force of the clamp 180 insufficiently clamps the edges of the cloth 250 between the grooves 230,232. That is, limited slippage between the two groove members must be allowed. As shown in Figures 25b and 25c, when clamped, the two grooves cause the cloth to move in a serpentine path between the clamp groove members, and when the cloth is extended Give resistance.

When the elongate clamp assembly is operated, a skinless, solid foam topper layer 252 is placed on the fabric 250. Open polyester cloth (not shown) then topper layer 25
Placed directly above 2. Place the three layers in place,
The upper mold 152 is pressed against the lower mold 156 to stop the movement between the two molds at a "control distance" determined by an adjustable spacer stop 168a.
When the upper mold 152 is lowered in 2 to 4 seconds,
A low pressure, low temperature steam, a temperature in the range of about 210 to 212 ° F, is injected into the steam chamber 174 and then through the opening 176 to remove the cloth.
Make 250 soft. The steam is jetted for about 10 seconds. When the upper mold reaches the control distance, the low temperature, low pressure steam is stopped and the high pressure steam is injected into the steam chamber 158 to form the fabric and foam and melt the adhesive between the layers. The hot steam is about 248 ° F within the device (ie, measured in the manufacturing cover cushion) and is emitted from a superheater (not shown) located adjacent to the device at a temperature of about 450 °. . The hot steam is jetted into the cavity between the two molds for a time of about 1 to 12 seconds. After injecting steam, the two molds are separated and a negative pressure is applied to the lower mold for about 5 to 20 seconds to cool the fabric and foam as the upper mold is raised. After raising the upper mold, the solid open cloth was removed and the lower mold 156 crossed the rail 118 (Fig. 22).
Upper mold 15 via screw drive (not shown)
Rolled to a position below 4. The screw drive can be used to properly position the lower mold 156 without a stop.

Next two core foam layers 2 including foam core 258
54 and 256 (FIGS. 27 and 28) are placed in the contoured cover body formed by the topping layer 252 and the cloth 250. The core foam layers 254, 256 are a collection of foams already bonded to each other and having different densities. However, the core foam layer 254 is larger in area than the core foam 256 and constitutes a depending edge 260 (FIGS. 27 and 28) that hangs along the periphery of the layer 254.

The foam core 258 is placed in the lower mold 156 such that an adhesive of the type described above is applied to both the top and bottom surfaces of the foam core 258 and the layer 254 is overlaid on the topping layer 252 (thirty-fourth mold 156).
Figure). The size of the cavity in the shell composed of the cloth 250 and the topping layer 252 depends on the hanging edge 260 (34th
Along the perimeter of the figure) between the edges of the layer 256 and the topping layer 252. Hanging edge 260
The memory of the topper layer 252 is the deep rounded edge of the lower mold 156.
262 and the round side part 264. This emphasizes the shape of the rim of the cushion produced in this way and its Sakai. The total thickness of cloth 250, topping layer 252 and foam core 258 is such that when the molds are pressed together,
Thicker than the cavity formed between 154 and 156, these aggregates are compressed, allowing the lower mold surface 172 to
Shall take the shape of.

With foam core 258 in place, seat backing 266
Is overlaid on the layer 256 in the seat area and the lower mold 156
It reaches the top of the apron portion 218 (Fig. 30). A similar back lining 266a is overlaid on the back area. There is a gap between the two at the seat and back joints. This facilitates bending of the finished product 288 during handling and reduces the tendency of the cover cloth 250 to rise at the joints between the folded sheet and the back, thus increasing the cover hinge.
Supplement the joint of 250a (Fig. 29).

With all cushion elements in place, the mounting ring assembly 268 (FIG. 31) is mounted on the upper mold 154. The mounting ring assembly 268 is retained in the groove 246 of the upper mold 154 (FIG. 32). The mounting ring assembly 268 is composed of two horseshoe-shaped members 270 and 272 having a peripheral shape of a product chair cushion. Each of the horseshoe shaped members 270, 272 has fasteners 276 around which a plurality of studs 274 snap fit. The studs, snap-fit fasteners and mounting ring assembly secure the product cushion to the chair as described below. The two horseshoe-shaped members 270, 272 are mounted in the groove 246 of the upper mold 154, and the stud 274 and the snap fit fastener 276 are
It projects into the groove 246. Further, the flat bottom surface 278 (FIG. 33) of each of the horseshoe-shaped elements 270, 272 is directed downward toward the lower mold 156. The horseshoe-shaped elements 270, 272 are retained in the groove 246 by releasable clamping means associated with the upper mold. Such a clamping means may be a vacuum suction holder, a releasable mechanical holding device for holding a stud, a configuration in which the horseshoe-shaped elements 270, 272 are fitted in the groove 246, and the like.

The flat bottom surface 278 of each of the two horseshoe-shaped elements 270, 272
Is coated with a heat sensitive adhesive, preferably the granular adhesive described above. Place the mounting ring assembly on the upper mold 154,
Place the cloth and foam layers on the lower mold 156,
The upper mold 154 is lowered toward the lower mold 156 arranged at the left side position as shown in FIG. Similarly, with the same type of adjustment stopper 168a provided on the upper mold 154,
Two molds are held at the control distance described above, and steam is injected into the upper mold 154 through the steam chamber. The temperature of the steam at this time is measured within the cushion itself and
It is about 240 ° F. The steam is jetted for about 5 seconds to about 20 seconds. The vapor melts the respective adhesive between the backing 266 and the layer 256, between the layer 254 and the topping layer 252, and between each flat surface 278 of each horseshoe-shaped element and the backing 266, thus cushioning. Aggregates of materials are strongly bonded.

After the steam is cut off, a vacuum is applied to the lower mold for 20 to 50 seconds to cool the product parts to a temperature at which they can be handled by hand. The cushioning product is removed from the lower mold and placed in the cooling conditioning device 28 (Fig. 36).

The cooling conditioning apparatus 280 includes a mold 282 having the shape of a product cushion. The mold 282 includes a plurality of openings 284 penetrating the upper surface of the mold 282 and a means for applying a vacuum through the openings 284. When a vacuum is applied through the mold 282, the cover cushion product is dried and further cooled. While the cushion is being cooled and dried, a cutting member 285 having a knurled blade is lowered onto the mold 282, and the cloth web 2 along the peripheral edge of the cover cushion 288.
While leaving 92 as it is, the excess peripheral cloth 286 (FIG. 29) is cut from the product cushion 288 along the virtual dotted line 290.

The cutting member 285 is supported by the frame 292 above the mold 282. Four hydraulic cylinders 294 are suspended from the top of the frame 292, and a platform member 295 is suspended from the hydraulic cylinders 294. Next multiple legs 296
Hang downwardly from the platform member 295 and support the cutting member 285. When the cylinder 294 is operated, the cutting member 285 moves closer to the mold 282. Preferably, the elastic cutting surface 297 is located on the die 282 where the cutting member 285 contacts to prevent blunting of the teeth of the cutting member.

After the cover cushion 288 is conditioned and cooled, the web 292 is folded under the cover cushion 288 and secured to the mounting ring assembly 268 at the stable 291 (Figure 33). The cover cushion 288 can be snap-fit onto the chair frame 298 (Figure 35). The chair skeleton 298 has a plurality of openings 299 into which studs 274 are introduced and a plurality of openings 300 into which snap-fit fasteners 276 are introduced. The distance between each pair of openings 299, 3000 should not be greater than the distance between each pair of studs 274 and snap fit fasteners 276. Chair Bones 29
Eight openings 299,300 around 8 are aligned with the studs 274 and snap fit fasteners 276 spaced around the mounting ring assembly 268 to allow the cover cushion 288 to snap into the chair skeleton 288 easily. You can

In a third alternative embodiment, it is therefore a very quick and economical method whereby breathable cover cushions can be manufactured quickly and with a deep engraving effect. The entire cushion can be snapped onto the chair frame. There is no need to attach expensive cushions such as buttons or tufts or create engraved pattern effects. With a few workers, manufacture the entire cushion,
And it can be attached.

While a plurality of embodiments of the present invention have been shown and described, other embodiments will be apparent to those of ordinary skill in the art. Also in these examples, unless otherwise specified,
It is considered to be encompassed within the scope of the claims.

[Brief description of drawings]

FIG. 1 is a cross-sectional side view of a stampless designed for manufacturing the cover cushion of the present invention. FIG. 1A is a sectional view taken along the same plane as that of FIG. 1 with the cover cloth and the cushion arranged on the press of FIG. FIG. 2 is a side sectional view of the stamp press of FIG. 1, and is for showing a state in which the mold is closed in a sectional view. FIG. 2A is a side sectional view of the stamp press of FIG. 1, and is for showing the closed state of the mold with the cover cloth and the cushion in a sectional view. FIG. 3 is a sectional view of the lower mold used in the stamp press of FIG. 1 in a plane taken along the line III-III of FIG. 4 is an elevation view of the bottom of the upper die of the stamp press of FIG. 1 approximately along the plane IV-IV of FIG. FIG. 5 is a perspective view of a stamp press device used in an alternative embodiment of the present invention. FIG. 6 is a sectional view of a plane along the line VI-VI in FIG. FIG. 7 is a bottom view of one of the upper molds used in the correction method in the plane along the line VII-VII. FIG. 8 is a detailed elevational view of one half of the stamp press shown in FIG. 6 with the chair cushion, gerber cloth and cushioning material in place. FIG. 9 is a side sectional view of the stamp press of FIG. 8 and is for showing a closed state of a mold having a cloth and a cushion interposed therebetween. FIG. 10 is a detailed side elevational view of the stamp press shown in FIG. 8 with the mold closed and having a cover fabric and cushioning material disposed therebetween. 11 is a detailed side cross-sectional view of the stamp press of FIG. 6 in which the lower mold moves below the upper mold and the second layer of cushion material is molded at the method step of FIG. It is for showing the state of being arranged in the shell. FIG. 12 is a top view of a cushion material used for forming a cover cushion having an engraved pattern. FIG. 13 is a sectional view taken along the line XIII-XIII in FIG. FIG. 14 is a front elevational view of a chair cushion manufactured in accordance with any of the methods shown in FIGS. 1 through 4 and 5 through 11 in a substantially completed state. FIG. 15 is a detailed perspective view of a corner of the chair cushion illustrated in FIG. 14. FIG. 16 is a perspective view of an edge at a joint between the back portion and the seat portion of the chair of the chair cushion of FIG. FIG. 16a is a sectional view taken along the line XIVa-XVIa in FIG. FIG. 17 is a partial perspective view of the skeleton of the chair to which the cover cushion of the present invention is attached before the attachment of the chair cushion. FIG. 18 is a partial perspective view of the frame of the chair shown in FIG. 17 after the chair cushion is attached. FIG. 19 is a sectional view taken along line XIX-XIX in FIG. FIG. 20 is a sectional view taken along the line XX-XX in FIG. FIG. 21 is a sectional view taken along the same plane as FIG. 20 showing the cushion of FIG. 13 in the chair cover cushion shown in FIG. FIG. 22 is a side sectional view of a stamp press device used in the second alternative embodiment of the present invention. FIG. 23 is a perspective view of the front end of the lower die of the pressing device shown in FIG. FIG. 24 is a top view of the lower die of the pressing device of FIG. 23. Figures 25a to 25c are cross-sectional views along line XXIV-XXIV of Figure 23 of the extension clamp assembly showing various positions during operation. FIG. 26 is a detailed perspective view of a clamp used for the press Shimokawa die of FIG. 22. FIG. 27 is a top view of a foam cushion used in the method of the third alternative embodiment of the present invention. FIG. 28 is a sectional view taken along the line XXVII-XXVII in FIG. FIG. 29 is a partial elevational view of a chair cushion product manufactured according to the third embodiment of the present invention. FIG. 30 is a sectional view taken along the plane of FIG. FIG. 31 is a top view of two retainer members used to secure the cushion to the chair frame. 32 is a bottom elevation view of the upper die of the stamp press of FIG. 23 taken along the line XXXII-XXXII of FIG. FIG. 33 is a detailed sectional view of the edge of the chair cushion of the present invention adhered to the retainer member shown in FIG. 31. FIG. 34 is a detailed sectional view of the chair cushion of the present invention at the time of manufacturing. FIG. 35 is a detailed cross-sectional view of the chair cushion of the present invention attached to the frame of the chair by the retainer member shown in FIG. 31. FIG. 36 is a perspective view of the cooling adjusting apparatus used in the third embodiment of the present invention. 10 is press, 12, 114, 156 is lower mold, 14 is raised, 16,
120, 126, 154 upper mold, 18 cover cloth, 20 topping layer, 22 cushion material, 26 backing, 28 cavity, 48, 158, 174 steam chamber, 68 retainer ring

 ─────────────────────────────────────────────────── --Continued from the front page (56) References JP-A-61-176387 (JP, A) JP-A-62-146614 (JP, A)

Claims (4)

(57) [Claims] 1. A method of manufacturing a cover cushion having an engraved pattern, a step of preparing a first mold having an effect of giving an engraved pattern, a step of preparing a second mold, and at least one side of a foam cushion. Applying an air-permeable heat-sensitive adhesive to the mold, arranging the cushion between the molds with one side facing the first mold, and covering cloth on the one side of the cushion. Placing a ring around the cloth so that the ring presses the edge of the cloth against one of the molds, and pressing the molds against each other. A step of forming an enclosed space having substantially the shape of a cover cushion product between them, jetting heated steam into the enclosed space, and applying a negative pressure to the cushion assembly. Removing the vapor after contact with the temperature of the vapor is sufficient to activate the adhesive to bond the fabric to the cushion and to give the cushion a shape. To a high temperature, the cloth and the cushion are given the shape of the engraved pattern by the mold,
The method of manufacturing a cover cushion, wherein the peripheral edge retaining ring restricts movement of the cloth into the space and prevents excess cloth from entering the space and causing wrinkles. 2. A method of manufacturing a cover seat cushion, the step of preparing a first mold having a shape on one side of the seat cushion, and the step of preparing a second mold having a shape on the opposite side of the seat cushion. A step of disposing a plurality of retainer elements around the mold and one side, a step of applying an adhesive to the cushion material, and a step of disposing a layer of cloth and cushion material so as to overlap between the molds. Pressing the molds toward each other, pressing the retainer element against one or the other of the molds so that a portion of the cloth is between each retainer element and one of the molds. Holding and suitably applying pressure to each of the retainer elements to cause the cloth to slide in a controlled amount between each retainer element and the mold against which they are pressed, Method for producing a cover sheet cushion, characterized in that Ranaru. 3. A method of manufacturing a cover sheet cushion, comprising: preparing a first shape mold; preparing a second mold; arranging a cover cloth between the molds; Placing on top of a fabric, a polymer foam layer coated on both sides with a heat-sensitive adhesive, and placing a fabric backing on the foam layer, sandwiching the foam layer between the cover fabric and the backing. Embedding, placing a mounting ring device coated with a heat activated adhesive around the periphery of the backing, pressing the molds together to form a cavity between them And a step of injecting heated steam into the cavity, and a method of manufacturing a cover seat cushion, comprising: 4. A method of manufacturing a cover cushion having an engraved pattern, a step of preparing a first mold having an effect of giving an engraved pattern, a step of preparing a second mold, and the first mold. The second mold and the second mold are movable so that a cavity can be formed between them, a cover cloth is arranged between the molds, and the cover cloth Providing cushioning means having a thickness such that the total thickness is greater than the distance between the molds in the cavity at the point where the molds are closest to each other, the cushioning means and the cover cloth Disposing an air-permeable heat-sensitive adhesive between the cloth, disposing the cushion between the cloth and the second mold, and pressing the mold together to press the cloth in the cavity. When Compressing the cushion means to cause the cloth and the cushion means to assume the shape of the first mold; and the adhesive melts and activates to shape the cushion and the cloth. Injecting heated steam into the cavity at a temperature and for a sufficient time, but for a length of time such that the adhesive does not flow out from the joining line between the cover cloth and the cushion, and the cushion And a step of cooling the cover cloth to solidify the adhesive, the method of manufacturing a cover cushion, comprising: