RU2342895C2 - Method for manufacture of cushioning material from molded polymer product (versions) and cushioning material (versions) - Google Patents

Abstract

FIELD: technological processes.

SUBSTANCE: cushioning material from molded polymer product has three-dimensional structure with bubbles and preset bulk density. Three-dimensional structure is shaped through engagement, cabling and assembly of adjacent, randomly located loops or spirals of solid and/or hollow continuous threads and/or short threads from thermoplastic polymer. Structure is heated in puncheon or matrix of die mold up to temperature that is sufficient for softening by three-dimensional structure. Structure is compressed to thickness that corresponds to length of puncheon travel and hardened by cooling.

EFFECT: higher accuracy and simplification of item molding process.

10 cl, 42 dwg

Description

FIELD OF THE INVENTION

The present invention relates to a cushioning material from a molded polymer product having a structure with spring properties, a method of manufacturing such a material and molds used in the manufacture of cushioning material, in particular to a method of manufacturing a molded polymer product (product) having a structure with spring properties, possessing high impact strength and bearing capacity, satisfying special and general requirements with respect to shape and size in various industry, in particular support material that you can sit on or lie down, such as seats in motor vehicles, motorcycles, bicycles, electric trains and airplanes, saddles for riding, chairs, sofas and beds, and a method of manufacturing shock-absorbing material, the disposal of which inexpensive and easy, the manufacturing cost is low due to the simplification of technological equipment, and the molding accuracy is higher, as well as the equipment necessary for the manufacture of shock-absorbing mat rial.

State of the art

Currently, polyurethane foam is the main material for seat and bed cushions in motor vehicles, motorcycles, bicycles, electric trains and airplanes. Typically, pillows are used in one form or another as supports on which you can sit and lie down, regardless of whether they are exposed to vibration during use or not. Indeed, polyurethane foam is widely used in a variety of cases, and the prevalence of this material is largely due to the ease of manufacture and low cost.

One such cushion was disclosed, for example, in Japanese Patent No. 2,995325, which provides a cushion lining for a car seat. In this cushion lining, the working surface is made of a single layer of foam with high elasticity, and the foam with high elasticity is made of polyurethane foam containing 10 weight% or less of tolylene diisocyanate (TDI), and the rest of the isocyanate is diphenylmethanediisocyanate. Japanese Patent No. 2,548,477 proposes a cushion design obtained by sintering together polyester fibers having a high melting point with a thermoplastic elastomer with a low melting point. Japanese Open Patent Publication (Kokai) No. 2000-51011 proposes a cushion which is obtained by partially bonding synthetic fibers and natural fibers with a thickness of 1 to 20 denier to each other by means of synthetic rubber glue or by chemical bonding.

Usually, when a person sits on a seat made of polyurethane foam, his weight tends to concentrate at one point to such an extent that the polyurethane foam is pressed deep in this place. In this case, the state of equilibrium becomes unstable, and with a long stay in such a seat a person gets tired. The main reason for this is as follows. In the manufacture of products from polyurethane foam, the foamable material is placed in the mold and foams evenly, which ensures uniformity of density and rigidity of the material. With this technology, it is difficult to obtain a product whose individual parts have different densities and stiffness in accordance with their functions. Moreover, since polyurethane foam has such softness and elasticity that when a person presses the polyurethane foam seat with his weight, he feels back pressure on the buttocks from the hard bottom and vertical swing, his legs can become stiff and with prolonged sitting the feeling of fatigue becomes strong. Take, for example, a polyurethane seat for a car or motorcycle. There are many requirements for the design and manufacturing technology of such a seat, but the density of the material itself is so uniform that when a person sits on the seat, the pressure distribution on the surface of the seat is constantly changing, and therefore polyurethane foam may not be suitable for the functions of the seat. The manufacture of products from polyurethane foam is usually carried out by foaming, and therefore the material is characterized by uniform springiness, or it is given a number of very different shock-absorbing properties. Therefore, for a product made of polyurethane foam, it is difficult to change its shock-absorbing properties in accordance with the requirements. The motorcycle seat must change its shock absorbing properties according to the type of motorcycle, for example, depending on whether the motorcycle is intended for tourism, road racing or motocross, or depending on the rider’s posture while riding. Due to the fact that the seat cannot change its shock-absorbing properties according to the type of motorcycle or the pose of the rider, the rider must either carry weight on the seat or lift off it during the race, which, if repeated for a long time, can lead to a rise in the overall center severity and imbalance.

In addition, there are difficulties with the processing of polyurethane foams due to the fact that these are thermosetting plastics. Therefore, the only way to process polyurethane foams is to grind them into chips and then glue them to obtain a material that is glued polyurethane foam chips / chips, or they can be burned to produce heat. The disposal of polyurethane foam includes landfill or incineration. However, when using polyurethane foam it is not possible to obtain stable soils due to their low density and softness, so the choice of suitable burial sites is limited. Polyurethane foams can be processed into fine particles or powder, which, however, requires additional production and financial costs. In addition, when burning polyurethane foam, gaseous hydrocyanic acid is formed, which causes damage to the combustion plants and requires high costs to neutralize. As mentioned above, it is difficult to ensure the disposal of polyurethane foams in accordance with the relevant legislative requirements without harming the environment during and after disposal.

In addition to the above, other problems described below are associated with polyurethane foams. To obtain a molded part from polyurethane foam, a foamable material is blown into the mold (for example, for three minutes), after which the molded part is separated from the mold. The separation procedure is complicated, and molding takes a long time. There are difficulties with cleaning polyurethane foam products. This is because the amine catalyst used in the process remains in the pores of the foam and is a source of unpleasant odor. Polyurethane foam retains heat, creates a stale atmosphere, and there is a concern that if it is exposed to bright light for a long time, it may ignite. Polyurethane foams are characterized by a low level of environmental safety.

Despite the fact that 2020 is set as the deadline for the use of chlorofluorocarbon-freon (CFC) substitutes used as foaming agents, no other substance has yet been found that exceeds the performance characteristics of the CFC substitute. Tolylenediisocyanate (TDI), an isocyanate commonly used in the production of soft polyurethane foams, is very harmful, and should be used at concentrations of no higher than 0.005 ppm according to Japanese Labor Ministry Notice No. 25. In many industries, due to the lack of strict control when using TDI, the health of workers is harmed.

The aforementioned seat cushion lining for a vehicle disclosed in Japanese Patent No. 2995325 has improved soft polyurethane characteristics, but is not free from the disadvantages of polyurethane foams. The design of the cushion proposed in Japanese Patent No. 2548477 presents difficulties with processing due to sintering of polyester fibers with a high melting point by means of a thermoplastic elastomer with a low melting point, which complicates the technology and cost of production. Although the cushion proposed in Japan's Open Patent Publication No. 2000-510111 (Kokai) has the advantages of excellent breathability and the ability to clean, it also has the disadvantages of low durability, complexity of manufacturing technology and high manufacturing costs. In addition, since rubber glue and polyurethane foam with chemical bonds of polymers are thermosetting polymers, and the pillow contains more than one detail, it is difficult to process it.

At present, however, despite the large number of problems described above related to the use of polyurethane foams, there is no other material for replacing polyurethane foam, which is equally cheap and suitable for use as a seat cushion material in motor vehicles, motorcycles, bicycles, electric trains and airplanes and beds.

Disclosure of invention

In view of the foregoing, the aim of the present invention is to provide a method for manufacturing a shock-absorbing material, consisting of a molded polymer product having a structure with spring properties, in particular, a material suitable for use in the manufacture of various supports on which you can sit and lie, for example seats motor vehicles, motorcycles, bicycles, electric trains and airplanes, riding seats, chairs, sofas and beds. More specifically, it is an object of the invention to provide a method for manufacturing a molded product (s) in which the molding process is simplified, the molded product can be of any shape and size, production costs are small, and pillows can be easily manufactured to satisfy the widest variety of requirements for spring products, for example, resistance to punching and the ability of the person sitting on them to distribute their weight evenly on the work surface so that even prolonged sitting is not tiring They must be resistant to shock and high bearing capacity. In particular, the aim of the invention is to provide a method for manufacturing a molded product characterized by the simplicity of technological equipment, low production costs, increased molding accuracy, low labor intensity and allowing to obtain finished products in which the ends of the product will not disintegrate even without special application of trimming or rounding operations after molding .

To achieve these goals, in accordance with the present invention, there is proposed a method of manufacturing a cushioning material from a molded polymer product having a spring-loaded structure, in which a three-dimensional structure is formed with voids and a given bulk density, brought into contact, twisted and assembled together adjacent randomly located loops or spirals (curls) of continuous and / or hollow continuous (long) threads (fibers) and / or short threads obtained from thermoplastic Limeray then heated male mold of the mold or the mold cavity and / or three-dimensional structure to a temperature sufficient to soften the three-dimensional structure, then compresses the three-dimensional structure of the indentation punch in a matrix to ensure intimate contact therebetween and then curing the three-dimensional structure by cooling.

In a preferred embodiment, the method further comprises the step of removing excess ends of the three-dimensional structure protruding between the punch and the die when they are compressed by means of a thermal cutter, whereby the ends are simultaneously cut and fused.

In a preferred embodiment, continuous and / or short filaments include filaments (fibers) made of commonly used plastics (polyolefins, polystyrene polymers, methacrylic polymers, polyvinyl chloride, etc.) or structural plastics (polyamide, polycarbonate, saturated polyester, polyacetal, etc.) . In a preferred embodiment, they are made, for example, from thermoplastic elastomers, for example, polyethylene (PE), polypropylene (PP) and nylon.

In particular, in a preferred embodiment, the yarns are made from a mixture obtained by adding a vinyl acetate polymer (VAC), an ethylene vinyl acetate copolymer (EVA) or styrene-butadiene styrene (SBS) to a polyolefin polymer, for example PE or PP. The weight ratio in the mixture with vinyl acetate of the polyolefin polymer to VAC or EVA is 70-97% to 3-30%, preferably 80-90% to 10-20%. If the VAC content is equal to or lower than 3 weight%, then the toughness of the three-dimensional structure will be low. Otherwise, if the weight content of VAC is equal to or higher than 30%, the thermal characteristics of the structure will deteriorate. The weight ratio of polyolefin polymer to SBS is 50-97% to 3-50%, and in a preferred embodiment, 70-90% to 10-30%. The polyolefin polymer may be a regenerated polymer.

Long and / or short threads can be solid or hollow. If continuous and / or short threads are hollow, such threads are more preferable, since the air enclosed in the cavities of the threads acts as a spring, imparting to the threads the properties characteristic of a spring. The air enclosed in the cavities of the threads also weakens the tendency to crease of the threads, manifested after prolonged and intensive use. The air enclosed in the cavities of the threads also retains the rigidity of the three-dimensional structure. The cavity of the threads can serve as a continuation of each other, or can be independent of each other. As an example, we can cite yarns in which each of the individual hollow fibers can have cavities with partitions between adjacent cavities. If a mixture of continuous filaments and hollow strands is used as the filament material, then the ratio between solid filaments and hollow filaments is, in a preferred embodiment, 0-50: 50-100. Further, if hollow threads are used in the central part of the structure and are covered with solid threads, then the resulting structure will have the required tactile properties.

In a preferred embodiment, continuous continuous and / or short filaments have a diameter of from 0.3 to 3.0 mm, in particular from 0.7 to 1.0 mm. If a continuous continuous filament has a diameter of 0.3 mm or less, the filaments lose their elasticity and sinter with each other so much that the void ratio becomes unacceptably low. Otherwise, if continuous continuous filaments have a diameter of 3.0 mm or more, then the filaments become so elastic that they do not form loops and curls, do not sinter with each other, which leads to a decrease in strength. If the threads include hollow threads, then in a preferred embodiment, their diameter is from 1.0 to 3.0 mm, in particular from 1.5 to 2.0 mm. If the void ratio is equal to or lower than 10%, then the advantage of reducing the weight of the product with respect to volume due to the use of hollow threads is lost. On the contrary, if the void ratio is equal to or exceeds 80%, the hollow threads will lose their cushioning properties.

The bulk density of the molded polymer product having a structure with spring properties can be from 0.005 to 0.08 g / cm ³ or less, in a preferred embodiment, from 0.02 to 0.06 g / cm ³ . If the bulk density of this material is 0.005 g / cm ³ or less, the product will have a reduced strength. On the other hand, if the bulk density of the material is 0.08 g / cm ³ or more, the advantage of the low weight of the yarn product relative to its volume will be lost. A molded polymer product having a structure with spring properties may have a uniform density throughout the structure, or the structure of the product may contain a high density substructure and a low density substructure, alternating at a certain interval. In the latter case, the low density substructure may have a density of from 0.005 to 0.03 g / cm ³ , preferably from 0.008 to 0.03 g / cm ³ , and best of all, from 0.01 to 0.03 g / cm ³ . The high density substructure may have a density of 0.03 to 0.08 g / cm ³ , in a preferred embodiment, 0.04 to 0.07 g / cm ³ , and in the most preferred embodiment, 0.05 to 0.06 g / cm ³ .

The void ratio of the molded polymer product having a spring-loaded structure can be from 96 to 99%, preferably from 97 to 99%, and most preferably from 97 to 98%. To ensure the elasticity and strength of the structure as a pillow, as well as to reduce its weight, the void ratio should be within the above limits, [void ratio,%] = (1- [bulk density] / [polymer density]) × 100

The cushioning material, in a preferred embodiment, is obtained by layer-by-layer combining molded polymer products having a spring-loaded structure into a layered structure. In a preferred embodiment, the cushioning material is used as seat material in motor vehicles, motorcycles, bicycles, electric trains and airplanes, riding seats, chairs, sofas and beds. The cushioning material can be used instead of foam urethanes as a support material on which to sit and lie, regardless of whether the support is exposed to vibration or not.

In particular, when the shock-absorbing material is used as the seat material of a vehicle or motorcycle that is subject to intense vibrations during operation, it is preferable to use a shock-absorbing material, since it can be easily adapted to various individual requirements (for example, supporting the load) of the vehicle, since the thickness of the material can be controlled.

The mold matrix in a preferred embodiment is made of concrete. When using a concrete mold, you can do without release agents, which reduces production costs. The mold punch, in a preferred embodiment, is a base to which shock absorbing material can be attached. In this case, there is no need to prepare a separate mold punch, which reduces production costs, and the molding accuracy will be improved. Cooling can be natural or forced. In a preferred embodiment, forced cooling is based on the use of water.

The cushioning material in accordance with the present invention is more suitable for recycling than polyurethane and is better suited to meet the needs of the consumer in relation to the performance of specific functions than polyurethane. The shock absorbing material is molded by compression (in the mold under pressure). Therefore, it is possible to create a product whose form corresponds to the form of a given user, or by order of the user, which is an additional advantage of the product. Moreover, by choosing the diameter of the yarns constituting the molded polymer product having a spring structure, the yarn material and denier, bulk density and void ratio, a molded polymer product with the desired spring properties can be obtained. Although the individual filaments constituting the cushioning material according to the invention are equivalent to each other with respect to the spring properties, they can impart different properties to the product, being pressed differently during compression molding (pressure). Therefore, it is possible to create a cushioning material in which the individual parts have different cushioning properties and in which, when applying weight, the weight receives different support, depending on the place with which it is in contact. Moreover, by adjusting the stroke of the mold punch, it is possible to set the desired thickness of the molded product.

In particular, the mold punch may include a base (which may be a component of the cushioning material constituting the product) to which a molded polymer product having a spring-loaded structure can be attached. At the same time, there is no need for a specially made mold punch, which reduces production costs. Moreover, since part of the product is used as an element (molding part) of the molding device, the molding accuracy is improved. In a preferred embodiment, the vertical movement of at least one of the two joined parts of the mold is carried out by means of a jack of the type "pantograph" (jack-pantograph). Compared to the hydraulic cylinder and pneumatic cylinder, which are used in conventional devices for molding polyurethane products, the above-mentioned design is so simple that its use will help reduce production costs, as well as simplify process equipment. In a preferred embodiment, the mold punch design can withstand a load of one ton or more. In the event that the mold matrix is made of concrete, it will be possible to avoid the use of release agents that would otherwise be necessary, as well as to reduce production costs compared to manufacturing technology that uses metal molds for the same purpose. Moreover, since the molding process is simplified and the time required for molding is reduced, mass production of the cushioning material becomes possible. Cooling can be achieved by free cooling or forced cooling. In a preferred embodiment, forced cooling is based on the use of water.

According to the invention, there is provided a concrete mold matrix for producing a molded polymer product having a spring-like structure made of a cured concrete mass poured into the space inside the frame made of a reference mold matrix suitable for molding a polymer product having a structure with springy properties.

Typically, in the manufacture of a molded polymer product having the spring-loaded structure described above, the edges of the product disintegrate after molding, so trimming or rounding is required after molding, which is inconvenient. In the molded polymer product presented here having a spring-loaded structure, trimming and melting of the product edges after pressing can be carried out by a thermal cutter, which allows us to abandon the above-mentioned trimming procedure and eliminate unnecessary operations, while cutting off excess edges protruding from the three-dimensional structure with a thermal cutter into the gap between two joined parts of the mold and at the same time fuse together the open ends of the threads at the edges.

In accordance with the foregoing, according to the invention, there is provided a cushioning material from a molded polymer product having a structure with spring properties, comprising at least two layers of superposed sheets, each of which contains a three-dimensional structure, which have the same or different spring properties, consist of contiguous, twisted and assembled adjacent randomly located loops or spirals of continuous and / or hollow continuous threads and / or short threads obtained from thermopiles elastic polymer, and were heated in the mold punch or in the mold matrix to a temperature sufficient to soften the three-dimensional structure, compressed while the two parts of the mold joined together and cured by cooling.

In accordance with another embodiment of the invention, there is provided a cushioning material from a molded polymer product having a spring-loaded structure, comprising a three-dimensional structure consisting of contiguous, twisted and assembled adjacent randomly spaced loops or spirals of continuous and / or hollow continuous threads and / or short threads obtained from a thermoplastic polymer, and having on its upper and lower surfaces at least two bulges formed on predetermined linear regions by means of a thread of thermoplastic polymer stitching the edges of each region and shortened by pressure.

In addition, a method for manufacturing a cushioning material from a molded polymer product having a structure with spring properties is provided, in which the thermoplastic polymer melt is extruded into yarns and brought into contact, twisted and looped together randomly arranged loops or spirals of continuous threads, with the formation of a three-dimensional structure with voids and a given bulk density, then cut off the edges of a three-dimensional structure forming a molded polymer product having structures with springing properties, to obtain a U-shaped or V-shaped profile, and sew the edges obtained with a thread from a thermoplastic polymer, and also sew with a thermoplastic polymer thread the edges of predetermined linear regions on the upper and lower surfaces of the three-dimensional structure, and shorten the threads with pressure.

In a particular embodiment of the method, the three-dimensional structure is placed in the mold matrix, the mold matrix and / or the three-dimensional structure are heated to a temperature sufficient to soften the three-dimensional structure, the three-dimensional structure is compressed by pressing the mold punch into the mold matrix to ensure a dense of the contact between them, cool the three-dimensional structure with giving it constant springing properties and sew the edges of the thermoplastic polymer with a thread in predetermined linear areas on the top three-dimensional structure and the bottom surfaces of the yarns with subsequent shortening pressure.

Brief Description of the Drawings

The objectives and advantages of the invention will become apparent from the following detailed description of preferred embodiments of the invention with reference to the attached drawings, in which:

Figure 1 is a perspective view of a cushioning material attached to a base 4.

Figure 2 is a front view and a rear view of the cushioning material 1 attached to the base 4, respectively.

Figure 3 is a side view of a motorcycle 10 equipped with a seat with cushioning material 1.

Figure 4 is a perspective view of the base 4 at different angles.

Figure 5 represents the first pressing step performed in relation to the cushioning material 1.

6 represents the first pressing step performed with respect to the cushioning material 1, shown at a different angle.

7 represents a second pressing step performed in relation to the cushioning material 1.

Fig. 8 represents a second pressing step performed with respect to the cushioning material 1, shown at a different angle.

Fig.9 represents the third pressing step performed in relation to the cushioning material 1.

Figure 10 illustrates the step of attaching the cushioning material 1 to the base.

11 is a flowchart of steps necessary for manufacturing a molded polymer product 30 having a structure with spring properties (hereinafter referred to as spring or spring structure).

12 is a perspective view of an apparatus for manufacturing a spring molded polymer product 30 in accordance with the present invention.

Fig.13 is a perspective view of another device for manufacturing a molded polymer product 30 with a spring structure, in accordance with the present invention.

Fig. 14 is a perspective view of another device for manufacturing a spring-loaded molded polymer product 30 in accordance with the present invention.

Fig. 15 is a cross-sectional view of other spring-molded polymer products 30 in accordance with the present invention.

Fig. 16 is a cross-sectional view of still other spring-molded polymer products 30 in accordance with the present invention.

17 is a rear view of the mold 622 and its axonometric image.

Fig. 18 is a cross-sectional view of a molded polymer product 30 with a spring structure and threads 31.

19 shows cross sections of another cushioning material 1, in accordance with the present invention.

20 shows cross sections of yet another cushioning material 1, in accordance with the present invention.

FIG. 21 represents another embodiment of the pressing necessary for molding the cushioning material 1.

FIG. 22 represents yet another embodiment of the pressing required to form the cushioning material 1.

23 is an example of a pressing process with respect to cushioning material 1 using conventional equipment.

24 is another example of a pressing process used with respect to cushioning material 1.

Fig. 25 is another example of a pressing process applied to cushioning material 1.

Fig. 26 is another example of a pressing process used with respect to the cushioning material 1, using conventional equipment.

The implementation of the invention

As is clear from the explanations for the axonometric image shown in FIG. 1 and the front and rear views shown in FIGS. 2a and 2b, the cushioning material 1 is obtained by preparing a thermoplastic polymer (for example, a thermoplastic elastomer), for example, a composition obtained by mixing, to for example, a polyolefin polymer, for example PE, PP, etc., with VAC, EVA or SBS, and processing the composition into a molded polymer product 30 with a spring structure or three-dimensional structure, and molding the article or structure by compression.

Description of molded polymer product 30 with spring structure

First, a molded polymer product (preform) 30 with a spring structure will be described.

The spring-molded polymer product 30 used in the present embodiment is a three-dimensional hollow structure obtained by contacting (joining), twisting and gathering (joining) adjacent randomly located loops and curls of long and / or short threads ( just yarns 31) made from the above composition. The threads are numerous loops and curls (see local view A in Figure 1, where the details in question are presented in enlarged form). In this embodiment, the spring-molded polymer product 30 comprises hollow threads 31, a cross-section 31a of which is shown in FIG. 1 (see local view B in FIG. 1, showing this enlarged detail).

In this embodiment, the bulk density of the three-dimensional structure can be from 0.005 to 0.03 g / cm ³ , in a preferred embodiment, from 0.008 to 0.03 g / cm ³ , and in the most preferred embodiment, from 0.01 to 0, 03 g / cm ³ . The void ratio of the three-dimensional structure can be from 96 to 99%, in the preferred embodiment, from 97 to 99%, and in the most preferred embodiment, from 97 to 98%.

Description of shock absorbing material 1

The following is a description of the cushioning material 1.

The cushioning material 1 is obtained by pressing a molded polymer product 30 with a spring structure. The cushioning material in this embodiment is mainly used as the material of bicycle seats with a motor (for example, motorcycles 10).

The cushioning material 1 has a two-layer structure consisting of two sheet layers (blanks) - the upper layer 2 and the underlying layer 3. These two layers can have the same spring properties or different spring properties. Two sheet layers, in a preferred embodiment, are bonded to each other with adhesive or double-sided adhesive tape. Different springing properties can be imparted to two sheet layers or different parts of each layer by a corresponding change in the density of the spring-molded polymer product 30, its material and / or the diameter of the product strands constituting the sheet layers. In a preferred embodiment, the two layers have different spring properties so that, for example, the top layer feels more rigid, while the underlying layer feels softer to the touch.

According to this particular embodiment, the upper sheet layer 2 is less rigid (softer) than the underlying sheet layer 3. This is because the underlying layer has to be attached to the base 4, while the upper sheet 2 enters direct contact with the rider's buttocks when riding. In a preferred embodiment, the upper sheet layer 2 on its upper surface has a bulge, which is given a shape compatible with the shape of the buttocks of the rider, located on the seat in a working position. On the other hand, since the underlying sheet layer 3 is attached to the base 4, it must be more rigid than the upper sheet layer 2. In a preferred embodiment, the shock-absorbing material has such a structure that its shape is maintained due to the rigidity of the underlying sheet layer 3.

The cushioning material 1 has a certain supporting ability due to the presence of an underlying sheet layer 3. A typical bicycle seat with a motor that uses foam urethane usually experiences a strong backward push from the road surface after an elastic downward movement in the direction of the road. To absorb this backward shock, conventional polyurethane foam motorcycle seats often include coil springs embedded inside the polyurethane foam. In accordance with the present invention, the seat has a two-layer structure: a softer upper sheet layer 2, designed to receive the weight of a person, and a more rigid underlying sheet layer 3, designed to absorb downward elastic displacements. This design feature avoids the use of coil springs. Accordingly, the seat in this embodiment has advantages in terms of weight and simplicity of design, and also that it does not require additional elements to absorb downward elastic displacements. Moreover, the mass of the seat is relatively small, which lowers its center of gravity and contributes to the stability of the rider's posture during the ride. In addition, by adjusting the stroke of the mold punch, it is possible to impart the required thickness in various parts to the cushioning material 1. Thus, by adjusting the stroke of the mold punch, it is possible to produce shock absorbing materials that differ in size, shape, and profile to obtain various holding characteristics.

Since the shock-absorbing material 1 consists of a molded polymer product 30 with a spring structure, its air permeability is so high that moisture does not accumulate in it. Moreover, if cooled or heated air is passed through a pipe from an air conditioner through the cushioning material of the motorcycle seat 10, the rider may be warmed or cooled during the ride. If the vehicle seat is equipped in this way, then this existing function can be used instead of installing special equipment.

The shape of the cushioning material 1 having a two-layer structure containing the upper sheet layer 2 and the underlying sheet layer 3 is not limited to that described with reference to the drawings, and can be any, in accordance with the requirements of the application. For example, the cushioning material 1 may have a single layer structure. Or the cushioning material may have a multilayer structure containing two or more layers. As for the cushioning material with a multilayer structure, at least one underlying layer can be made of synthetic rubber, and at least one of the layers (preferably the upper layers), in a preferred embodiment, are made of thermoplastic polymer. The shape of the bulge is not limited to the shape described above. The shape, profile and size of the product from the shock-absorbing material can be selected so as to most closely meet the requirements for product standards, their functions and individual customer requirements.

In a preferred embodiment, a coating cushioning material consisting of a molded polymer product 30 with a spring structure (sewn by hand or on a sewing machine) is applied over a cushioning material having a multilayer structure (for example, a top sheet layer 2 of cushioning material 1), and a capping material is used seat sheet. In this case, it is possible to create wave-like bulges, which are usually absent on seats formed by conventional molding, to give the shock-absorbing material such a shape, profile and size to best meet the requirements for product standards, functions and individual needs of the client. Thus, you can change the size, shape and profile of the motorcycle seat in accordance with the type of motorcycle and the shape of the body of the rider. More specifically, if the seat is for a motorcycle 10 or a motor vehicle whose driver (for example, a professional driver) imposes stringent posture requirements while riding, it is possible to change the size, shape or profile of the seat to suit the user's requirements so that the seat can exactly match his posture while riding and working, which will give an additional advantage to the seat.

Both the upper sheet layer 2 and the lower sheet layer 3 have a shape corresponding to the shape of the base 4. On the axonometric images in Figures 4a and 4b it is clearly seen that the base 4 forms the lower part of the motorcycle seat 10. The base 4 has a stop 4a with its front sides and bulge 4b at the back. The bulge 4b on its lower side has a fastener 4c, through which the seat is attached to the frame of the motorcycle 10. On the base 4 there are several (for example, six) rubber gaskets 4d attached to its lower side. Also, as can be seen from the drawing, there are many grooves and holes.

A device for manufacturing a cushioning material 1 and the corresponding method

Next, with reference to FIGS. 5-10, a description will be made of a device for manufacturing a cushioning material and a method representing an embodiment of the invention. A method of manufacturing a molded polymer product 30 with a spring structure will be described hereinafter.

1) Material feed step

Figure 5 shows a side view of the installation for the manufacture of shock-absorbing material 1. This drawing is used to illustrate the first step of pressing when forming the shock-absorbing material. 6 is a front view of the same installation, also illustrating the first molding step. As can be seen in FIGS. 5 and 6, one or more molded polymer product 30 with a spring structure is placed in the mold matrix 11 made of concrete (hereinafter, simply the mold matrix). At least two molded polymer products 30 used may have the same spring properties or different properties from each other. As shown above, each molded polymer product 30 is a three-dimensional structure with voids, obtained by contacting, twisting and collecting together adjacent randomly located loops and curls of threads 31 (see local view C in Figure 5, showing the threads in an enlarged view )

According to this manufacturing method, it is required to heat the molded polymer product 30 with a spring structure to a temperature higher than the softening temperature of the polymers constituting the yarn 31. To do this, hot water is supplied through the hot water supply line 13 to the cavity 12 formed inside the mold matrix 11 (in a preferred embodiment, the water has a temperature of 70 ° C or higher) for heating the molded polymer products 30 with a spring structure to soften them. When hot water is supplied to the cavity of the mold matrix 11, hot water penetrates into the molded polymer products 30 and heats them from the inside of the mold matrix 11. Alternatively, the mold matrix 11 may itself be heated by a heater. In this case, it is desirable to place the heat-conducting element (for example, a heater) inside the concrete walls of the mold matrix 11. In a preferred embodiment, the mold matrix 11 is coated with a heat-insulating material (for example, a box made of wood or foam). If it is necessary to heat the air (including air in the cavities, if the threads are hollow) surrounding the threads 31, forming a molded polymer product 30 with a spring structure, it is desirable to use additional heat coming from a heater built into the concrete walls of the mold matrix 11. Instead of a hot water supply line 13, a steam supply line 17 or the like may be used. When using the steam supply line 17, steam inlets are made in the wall of the mold matrix 11 so that steam can enter the cavity 12 inside the mold through the inlets. In a preferred embodiment, steam for heating the molded product is injected into the mold after closing the mold. This heating method is preferred because it provides uniform heat transfer to the molded product. When, in addition to heating, high pressure is also required for pressing, steam heating is more preferable, since steam not only heats the molded product, but can also act on it with pressure. Steam heating is also effective for applying pressure when heating the molded product, when the molded product has such a complex shape that it is impossible to create uniform pressure mechanically.

The preparation of the mold matrix 11 can be performed as follows. A framework is made of a suitable material, such as gypsum or the like. The frame is turned over and fixed on a horizontal plate. A release agent is applied to the frame or plate. The cement powder is mixed with water until a paste is obtained, the paste is poured into the space formed by the frame, after which the frame is removed, and the concrete mold remains. Namely, after the hardening of the cement paste, the frame is turned over to its original position, and the frame and the horizontal plate are removed, exposing the concrete matrix 11 of the mold. In the process of preparation, it is possible by creating a space under a horizontal slab attached to the frame, and by adjusting the height of this space to change the strength, rigidity and thickness of the concrete in the right way. For example, to increase the thickness of concrete, it is only necessary to lower the fixation position of the slab. Since concrete has high ductility and easily forms the required shapes when pouring into the hardening frame, the cost of manufacturing the concrete mold 11 of the mold is relatively small (1 / 50-1 / 100 of the cost of manufacturing a similar mold in the usual way). Concrete, among other things, makes it possible to produce matrix 11 of the mold of complex configuration, as well as mass production of the same mold with high accuracy. For example, for molding molds of the same size, one and the same frame can be used repeatedly. Further, since the concrete mold comes into close contact with the melt, only the tight closure of the mating parts of the mold allows the molding of the molded product, in which the degree of purity of the outer surfaces corresponds to the level achieved by abrasive polishing. If the frame has a relief on the inner wall, then this relief will be transferred to the corresponding outer wall of the molded product. Or if the mating parts of the mold are joined with the vinyl sheet laid between them, the outer surface of the molded product will have prints that match the texture or pattern of the surface of the vinyl sheet. Moreover, since the mold matrix 11 is made of concrete, it easily withstands the high pressure that occurs when pressing the shock-absorbing material 1, and its durability is so high that it can withstand tens of thousands of molding cycles. The weight of the mold matrix 11, in a preferred embodiment, is from 50 to 100 kg.

The mold punch 14 may include a base 4 and a punch platform 14a (see FIGS. 4a and 4b). The mold punch 14 is fixed at several points by means of fasteners to the distal end of the pantograph jack 15. The mold punch 14, driven by the pantograph jack 15, is joined to the mold matrix 11, creating pressure from above on the molded polymer a product 30 with a spring structure placed in the cavity 12 of the mold matrix 11. In a preferred embodiment, the strength of the mold punch 14 allows it to withstand forces of 10 tons or more. In this embodiment, several (eg, three) pantograph jacks 15 are attached to one mold punch 14. This increases the pressure applied to the molded product, and also the pressure is distributed over several (for example, three) points. The pantograph jack 15 can be controlled manually, or, if necessary, have automated control using a motor 15a. The proximal end of the pantograph jack 15 is attached to the lid 18, and the lid 18 is supported by struts 19 located on the upper edges of the mold matrix 11. The use of the jack-pantograph 15 makes it possible to simplify the design of the installation, which leads to lower costs. Instead of the pantograph jack 15, however, a hydraulic or pneumatic cylinder or the like may be used.

In a preferred embodiment, the mold punch 14 includes a base, which is also part of the final product, as its element. The base 4 is attached to the mold punch platform 14a, the lower part of the base facing the lower part of the platform. The upper surface of the mold punch platform 14a is attached by means of connecting elements to the pantograph jack 15. Since a part of the product (base 4) is also included as an element (mold punch 14) in the pressing device, it is only necessary to prepare the mold matrix 11, A separate preparation of the punch 14 of the mold is not required. In the usual technology of molding polyurethane foam products, it is required to separately prepare punches and molds of the mold. In the installation using the method in accordance with the present invention, since part of the product is an element of the mold punch, there is no need to manufacture a base plate and punch, which leads to cost savings and increased molding accuracy.

2) Mold compression process

FIG. 7 is a side view of an apparatus for manufacturing a cushioning material 1, which illustrates a second molding step used for molding the cushioning material, while FIG. 8 is a front sectional view of the same apparatus that illustrates a second molding molding step. As can be seen in the drawings in FIGS. 7 and 8, the pantograph jack 15, actuated, pushes the mold punch 14 (which acts on the base 4) downward, as shown by the arrows in FIGS. 7 and 8, compressing the mold to be formed. In this particular embodiment, the mold matrix 11 is mounted so that the mold punch can enter the cavity 12 to a greater depth. Namely, the mold matrix 11 can be set so as to allow the mold punch 14 to enter the cavity to the desired level. By converging the two parts of the mold, you can change the thickness of the shock-absorbing material in accordance with the specified requirements by changing the stroke of one part of the mold relative to the other. Thus, using the same pair of joined parts of the mold, it is possible to produce shock absorbing materials of various thicknesses. Needless to say, the density of cushioning materials can also be changed. As shown above, using the same pair of mating parts of the mold, it is possible to produce various shock absorbing materials that differ in density, spring properties and stiffness simply by adjusting the relative movement of the mating parts of the mold as desired.

In the installation shown, it is possible to easily adjust the thickness of the cushioning material 1 by changing the mutual movement of the mating parts of the mold. In the event that it is required to produce thin cushioning material 1, it is only necessary to establish the mutual displacement between two joined parts of the mold to the required small distance. On the other hand, if you want to make a thick cushioning material 1, you only need to establish the mutual movement between the two joined parts of the mold to the required increased distance. Thus, in this installation, it is possible to easily change the thickness of the shock-absorbing material 1. It is also possible to easily change the density, spring properties and stiffness of the shock-absorbing material. If the angle of inclination of the inner side walls of the mold matrix 11 (the inner side walls shown in the drawings are approximately perpendicular to the base), if necessary, is made smaller than shown in the drawings, it is possible to produce a shock-absorbing material whose profile has the required angle of inclination. The desired angle of inclination may, for example, be from 1/50 to 1/400 (for example, 1/200). Tilt can be done in or out. If the mold matrix 11 has a too large angle of inclination inward, it will be difficult to establish the relative displacement between the two mating parts of the mold of the desired size. Thus, it is possible, using the same pair of joined parts of the mold, to produce the same shock-absorbing materials 1 having different thicknesses required. For example, it is possible to produce shock-absorbing material in accordance with a specific individual order, that is, to produce shock-absorbing material that exactly meets the requirements of individual customers. With regard to the parts of the seat facing the inner surface of the thighs of the rider, it is desirable to manufacture these parts so that they have a higher density and stiffness due to the spring properties. This improves the cushioning ability and durability of the seat.

In general, the contour of the seat is determined by the pose of the rider during the ride and is more or less unchanged. The thickness of the seat, however, may vary depending on the type (required supporting capacity) of the motorcycle. Thus, it is necessary to adjust the thickness of the cushioning material 1 according to the type of motorcycle. If polyurethane foam is used as the cushioning material, it turns into a molded product during foaming. In this case, the molded product experiences uniform expansion during the molding process using the same molds. Thus, it is required to prepare several joined pairs of mold parts in the event that it is required to produce shock-absorbing materials having different densities and thicknesses. According to the method of the present invention, the problems encountered in conventional manufacturing technology of polyurethane foam products can be easily avoided.

3) Trimming process

Figure 9 shows a fragment of the image of the installation for the manufacture of shock-absorbing material 1, used to illustrate the third step of molding molding required for the manufacture of shock-absorbing material. As can be seen in the drawing in Fig. 9, after keeping the parts of the mold in a reduced state for a predetermined time, the thermal cutter 16 moves along the edges of the mold punch 14, removing the flange 32 protruding along the edges of the mold punch 14 (see local view of Fig. 9, where this part is shown in enlarged view), by trimming this flash with simultaneous melting of the ends of the flash threads. In conventional technology, the edges of the molded product are trimmed after molding to obtain the desired size, which complicates the operations required for this. In the method proposed in the invention, trimming the molded product is simple. In particular, since trimming is carried out at the step following pressing, it is possible to melt the open ends of the strands of filament to prevent their destruction during operation, which avoids the operation of removing the filament when adjusting the size of the molded product and simplify verification procedures after pressing.

4) The process of separating the molded product

Cold water is poured into the cavity 12 of the mold matrix 11 for curing the molded polymer product 30 with a spring structure. Water pours in sharply, and not gradually, due to which the solidification time is reduced. After the passage of time sufficient for the solidification of the molded product, it is separated from the parts of the mold. The molded product has hardened or not, is determined by the weakening of the pressure of the pantograph jack 15 and by checking the presence of a spring reaction on the part of the molded product. The absence of a spring reaction on the part of the molded product means that the molded product has sufficiently hardened. After that, cycles of alternately heating / cooling the mold matrix 11 and / or the molded polymer product are repeated. If the molded product consists of hollow threads, it is possible to prevent the spring back reaction of the product 30 by maintaining the equilibrium state of the air masses enclosed in the cavities of the threads.

In the event that the mold matrix 11 is made of concrete, the polymer, even when molten, does not adhere to the inner walls of the mold, thereby avoiding the use of a release agent. When using conventional molds in the pressing device, the temperature during the pressing process rises so sharply that the polymer melt easily adheres to the inner walls of the molds. To solve this problem, in the process of molding polyurethane foam products, it is absolutely necessary to use separation agents, which requires additional time and technological operations. In case the abutting parts of the mold are made of concrete, the molded product is so tightly in contact with the walls of the parts of the mold that mass production of copies having exactly the same dimensions and shape is ensured, even in the case of a complex shape.

5) Final operations

Figure 10 shows how the cushioning material 1 is attached to the base, the upper sheet 2 and the underlying sheet 3, prepared as described above, are placed one on top of the other, and their assembly is superimposed on the base 4. Thermally formed sheet 5 of vinyl faux leather is superimposed on the assembly and fixed with a bracket to the base 4. In another embodiment, the fastening of the sheet 5 of vinyl faux leather to the base 4 can be done with adhesive tape. If in the underlying sheet 3 during the molding process, it is permissible to have recesses (or grooves) that are captured by the corresponding recesses (or grooves) formed on the base 4, then it is possible to fix the assembly on the base without using a bracket or double-sided tape. The fastening of the layer of the upper sheet 2 to the underlying sheet 3 can be fixed by means of an adhesive or adhesive tape between two opposite surfaces. In another embodiment, the two sheets may have recesses or grooves on opposing surfaces that will engage with each other when connecting the two sheets. In this case, the connection of two sheets does not require the use of an adhesive or adhesive tape. It should be noted, however, that the assembly process of the upper sheet 2, the underlying sheet 3 and the base 4 may not require any special fastening procedure, since they are closed by a sheet of vinyl faux leather in the final operation.

A method of manufacturing a molded polymer product 30 with a spring structure

The following is a description of an example of the manufacture of a molded polymer product 30 with a spring structure, in accordance with the above.

As shown in the diagrams of FIG. 11, according to the method according to the present embodiment of manufacturing a spring-loaded molded polymer product 30, a polyolefin polymer, for example PE, PP or the like, and another polymer, for example VAC, EVA or SBS, are supplied in the corresponding amount through a drum, feed mechanism or dispenser, and polymer raw materials are mixed in dry form or dissolved in a solvent, mixed and granulated. The powdered mixture or granules are transferred to the feed hopper 21 or extrusion press 20. More specifically, polymer feeds, such as PP and SBS, are mixed by drum (Kato Scientific Instruments KR mixing device) at 40 rpm for 15 minutes.

Further, as shown in the axonometric image in Fig. 12, the mixture containing the polymer feed is fed through the feed hopper 21 into a uniaxial (with an axis diameter of 65 mm) extrusion press (extruder) 20. The mixture is melted at a given temperature (for example, from 200 to 260 ° C), the melt is mixed and subjected to liquid extrusion at a predetermined speed through a variety of dies, is picked up by a broaching device 23, which will be described below, and is formed into continuous and / or hollow continuous filaments 31 having a predetermined diameter (for example, from 600 to 90,000denier, preferably from 3,000 to 30,000 denier, and in the most preferred embodiment, from 6,000 to 10,000 denier). The yarns 31 in molten form loops with a diameter of 1 to 10 mm, preferably 1 to 5 mm, and then are removed by a broaching device inside the bath 25 (with water), while neighboring threads, in contact with each other under water, are mixed up, forming random loops. The contiguous and tangled parts of the threads are partially fused and bonded to each other. The yarns 31 may comprise solid yarns and hollow yarns in a predetermined ratio.

The thickness and bulk density of a three-dimensional structure or the mass of random loops can be set as needed by adjusting the distance between the pulling (receiving) rollers 24, 24 of the broaching device 23 in the bath 25. Three-dimensional structure (for example, with a thickness of 10 to 200 mm and a width of 2000 mm) obtained from threads 31 with the formation of a mass of randomly arranged curls and loops, solidified in water, is fed to another pair of pulling rolls 26, 26, and forms a molded polymer product 30 with a spring structure.

When the yarns 31, which have formed loops in the water, are brought out by the broaching device 23, the shock-absorbing properties of the resulting three-dimensional structure can be changed as necessary by adjusting the speed of the broaching device 23. The three-dimensional structure, if it is necessary to obtain a sufficiently high bulk density, must have a bulk a density of from 0.03 to 0.08 g / cm ³ , in a preferred embodiment, from 0.04 to 0.07 g / cm ³ , and in the most preferred embodiment, from 0.05 to 0.06 g / cm ³ . A three-dimensional structure, if a sufficiently low void ratio is required, should have a void coefficient of 91 to 97%, preferably 92 to 96%, and most preferably 93 to 94%.

The speed of movement of the threads by the broaching device 23 is set low at intervals of, for example, from 3 to 5 m, for example, by reducing the speed of rotation of the pulling rolls 24, 24 to a lower predetermined level at certain regular intervals. In this case, it is possible to obtain a molded polymer product 30 with a spring structure having a series of alternating regions with a high density and low density, repeated at regular intervals in the longitudinal direction (for example, from 30 to 50 cm), and regions with a high density are obtained when the threads move at low speed, and areas with low density are obtained when at high speed.

As shown in FIG. 13, if it is assumed that a three-dimensional structure, for example, a molded polymer product 30 with a spring structure, cannot be bent by draw rolls 24, 24, the speed of the broaching device can be set so that a three-dimensional structure is formed containing a number areas of high density and low density, and adjust the broaching device so that the three-dimensional structure can bend in areas of low density. The molded polymer product 30 with a spring structure obtained by the process described above is cut by a cutter 27 into pieces of the desired length. Bath 25 has inlet and outlet valves (not shown here).

FIG. 14 is a view of another device in which the cutter 127 is located in the water in the bath 125 below the drawer 123, and the conveying device 128, containing a conveyor with multiple spikes on the surface, is placed in the water in the bath 125 opposite the drawer. The conveyor, pricking pieces of the spring structure formed on the spikes, which are formed when cutting a three-dimensional structure, thereby holds them on its surface and carries them to predetermined places. The elements of the device corresponding to similar elements in the previous embodiment, have similar numeric designations with the addition, however, of 1 in the third digit category.

By the method described above, a molded polymer product 30 with a spring structure can be obtained having, for example, a bulk density of 0.03 g / cm ³ and a thickness of 50 mm. A three-dimensional structure can be made using substructures, each of which has one property or a combination of properties that differ from the properties of the others. Details of the actual manufacture of the molded polymer products 30 with a spring structure using the described method, and the results of the tests conducted with them can be found in EP 00-1-182-826AI or other publications of the authors of the present invention.

Other embodiments of the molded polymer product 30 with a spring structure

Molded polymer products 30 with a spring structure in other embodiments than those shown above will be described below. The process of their molding is based on the viscosity of polymer raw materials.

In the molding process of the polymer product 30 with the spring structure described above, it is possible to obtain a three-dimensional structure that contains parts that differ in cushioning properties by controlling the output speed (threads) and the heating temperature. For example, it is possible to obtain a molded polymer product 130 with a spring structure, as shown in Fig. 15a, where the cushioning ability is weakened gradually, or at predetermined intervals, as the test probe moves from the periphery of the product to its core. In this particular example, the periphery of the product is formed by the solid portion 130a, while the core is formed by the soft portion 130b. The distribution of the cushioning ability can be reversed, as shown in FIG. 15b in the spring-loaded molded polymer product 230, where the core consists of a solid portion 230a, while the outer portion 230b is softer. It is also possible to obtain a molded polymer product with a spring structure in which various damping properties are distributed by “spots” (for example, two spots) over the product, as illustrated by the product 330 shown in FIG. 15c.

A spring-molded polymer product similar to product 130 is suitable as a cushioning material for the seat of a motorcycle 10. Since the cushioning material 1 has rigid lateral surfaces, they correspond well to the bulges in the middle part of the rider’s thigh when the rider sits in the seat and assumes a pose normal ride. A spring-molded polymer product similar to product 230 is suitable as a helmet material. A single three-dimensional structure with a soft surface (in contact with the head) and a rigid core allows you to make hats (sun hats and helmets) that do not spoil the hair. These hats have advantages, as they prevent sunlight, but have excellent breathability.

The cushioning material of the seat can perform its functions if it has a sufficiently rigid outer surface in accordance with the weight applied to the seat and the deformation that this weight causes. In this case, it is possible to obtain a molded polymer product with a spring structure by preparing several thin three-dimensional structures, each of which has its own density, and folding them in a certain combination into a single layered structure, instead of producing a single three-dimensional structure containing parts having different density. When using this method, you can save in the amount of polymer necessary to create a spring structure, and increase productivity. For example, it is possible to obtain a molded polymer product with a spring structure 430 shown in FIG. 16a by preparing a three-dimensional structure 430a, placing another structure with a lower bulk density 430b below it, and another structure 430c with an even lower bulk density and bonding underneath all three structures into a single layered structure.

It is also possible to obtain a molded polymer product 30 with a spring structure 530, shown in Fig.16b, which is partially reinforced by cavities 530a (dividing walls), which are made in the structure by heating individual places from which the strands are melted. Cavity formation can be performed before or after compression molding. It is also possible to obtain a molded polymer product 30 with a spring structure shown in FIG. 16c, where in each cavity there is a latch 530b, for example, a metal clip. The latch may be inserted into the cavity before or after compression molding.

The diameter of the yarns 31 constituting the molded polymer product 30 with a spring structure does not have to be uniform. Even if a single shock-absorbing material is used for the seat, the weight applied to this part of it depends on what part of the seat this part occupies. An increase in the stiffness of this part can be achieved by changing the bulk density of this part, as well as by changing the diameter and / or stiffness of the threads that make up this part. In a preferred embodiment, for example, thick and / or stiff threads are distributed in the part that is in contact with the buttocks of the rider, and carries a significant portion of its weight when riding.

For the manufacture of a spring structure in which one part (for example, the central part) contains more thick threads than other parts, the mold 622 has dies, as shown in FIG. 17a, where the dies 622a corresponding to the central part have a larger diameter, than the remaining dies 622b. When using such a mold 622, the thick yarns 631 are extruded from the central part together with the usual thin yarns 31 extruded from the remaining parts, as shown in FIG. 17b. It is possible to create a spring structure in which the stiffness is changed in a complex way by means of the above-described mold.

It is also possible to create a cushioning material that contains yarns having the same thickness and bulk density as similar in construction but softer or stiffer than in a similar structure by using yarn material different from the material in a comparable structure. For example, if the cushioning material 1 is used for the seat of the motorcycle 10, different yarn material can be used according to the weight of the user, which will increase the market value of the seat.

It is also possible to weave the threads of the spring structure with natural fibers or metal wire to create a complex spring structure. By modifying the threads of the spring structure in this way, it is possible to improve, for example, thermal stability, the tendency to crease during prolonged use and the tensile strength of the threads, which is a weak point of the threads of synthetic polymers. In a preferred embodiment, for example, the yarns 731 are intertwined with a plurality of metal wires 733, as shown in the molded polymer product 730 with a spring structure shown in Fig. 18a. Also, in a preferred embodiment, the hollow threads 731 are combined with a metal wire not only by grafting, but also by threading the metal wires in the cavity of the threads, as shown in cross-sectional views of the combined threads in Fig. 18b and 18c.

Shock Absorbing Materials 1 Representing Other Embodiments

When the mold matrix 11 and the mold punch 14 are closed, compressing the preform of the molded polymer product 30 with a spring structure, it is possible to stepwise change the heating temperature to thereby create a spring structure in which the stiffness changes from one part to another. For example, it is possible to create a cushioning material 101, as shown in FIG. 19a, where the lower part 101a (the sheet part) has greater stiffness and the upper part 101b is soft. The edges 101c, in a preferred embodiment, are heated to give them rigidity. In a preferred embodiment, for example, the edge portions 101c, where the ends of the filaments curl from heating, are processed to give them a sheet shape when trimming. The edge portions 101 may fit snugly into the respective edges of the base 4. In a preferred embodiment, prior to assembly, the edge portions 101c are pulled apart and spring back to their previous state, mating with the corresponding edges of the base. This design allows you to attach the shock absorbing material to the base without the use of brackets, and also to separate from the base.

When the mold matrix 11 and the mold punch 14 are closed, compressing the preform of the molded polymer product 30 with a spring structure, the mold matrix 11 can be very hot to raise the temperature of the mold to such a level as to melt the surface of the molded product which, when hardened, forms a hard shell covering the molded product (molding of the surface layer). Using this method, only the uppermost layer 201a of the molded product or the molded polymer product 30 with a spring structure can be melted and hardened, as shown in FIG. 19b using the cushioning material 201, for which no further coating is required (for example, vinyl coating faux leather 5). This method can also be used to mold the dashboard using the polymer as the material. Namely, in accordance with the present method, it is possible not only to mold the product, but also to mold a solid surface layer around the molded product. In particular, if the cushioning material 1 must be watertight or solvent resistant or must have a protective coating, it is preferable to use a hot firing surface layer molding to form the surface layer 201a.

Since the shock-absorbing material 1, including the molded polymer product 30 with a spring structure, in accordance with the present embodiment, has high breathability, for this application it is more desirable to abandon the use of vinyl leather substitute 5 than to coat the shock-absorbing material 1 with skin. If a vinyl faux leather coating is not used, then, in a preferred embodiment, the spring-molded polymer product 30 is coated with a mesh 306, as shown on cushioning materials 301 in FIGS. 20a and 20b. Mesh 306 may be applied over cushioning material 310 after compression molding. In a preferred embodiment, the mesh 306 is made of a water-repellent material (e.g., plastic). In this case, the mesh 306 can maintain excellent breathability, and thus, the seat is convenient to use even in high humidity and in the rainy season. Especially this seat is suitable for use in buggies, which usually ride on sandy tracks. The mesh 306 prevents the destruction of the cushioning material 301 so effectively that it increases the durability of the seat. The mesh size of the grid 306 is not limited to what is shown in the drawing, but can be done by anyone. Vinyl leatherette 5 can be applied over mesh-coated cushioning material. This may be necessary if the seat is installed in an electric train and, in case of damage, to prevent foreign objects from entering the seat.

Colliding parts of the mold in other embodiments

In the above embodiments, the mold matrix 11 is located at the bottom and the mold punch 14 is located at the top, but this arrangement of the two parts of the mold may be reversed. If the opposite arrangement is adopted, the mold matrix 11 applies its weight to the molded product during the molding process, and this molding is formed by pressures developed both by the compression device and under the influence of the weight of the mold matrix. Both the mold matrix 11 and the mold punch 14, in a preferred embodiment, are made of concrete, metal or fiberglass reinforced plastic (FRP). In that case, if the heavier part of the mold is installed on top (pressure side) and fits into the opposite part located below, the weight of the upper part of the mold can be used for compression molding. For example, compression molding can be performed by installing one part of the mold made of heavier concrete on top and the other part of the mold made of lighter concrete below, or by placing a larger part of the mold on top and a smaller one part is below.

This embodiment includes a pantograph jack 15 for quickly applying uniform pressure to the molded article. However, if the compression molding utilizes the pressure generated by the weight of the heavier part of the mold placed on top, it becomes possible to dispense with the pantograph jack 15. For example, in the pressing apparatus shown in FIG. 21, the mold punch 114 is suspended on expansion joints 115 or similar elements, each of which contains spring material, and compression molding is carried out by lowering the mold punch 114 into the mold matrix 111 under its own weight, as shown by arrows in the drawing. In another embodiment, the mold punch 214 may be connected by a hinge 215 to the mold matrix 211, as shown in FIG. 22. The mold punch 214 opens at a predetermined angle, the polymer melt is poured into the cavity in the mold matrix 211, after which the punch is displaced as shown by the arrow in the drawing until it closes the cavity inside the mold matrix 211. Thereby, compression molding is performed using the weight of the mold punch 214.

On figa, 23b presents an example of the process of pressing the shock-absorbing material 1 using conventional molds.

Figures 24-26 relate to other embodiments. In the installations shown in these drawings, the vertical arrangement of the mold die and the die punch is reversed. In these installations, the weight of the concrete mold die 11 located on top serves to create pressure during compression molding. If the mold matrix 111 is suspended on expansion joints 115 made of spring material, compression molding can be done by docking with the mold punch 114 under its own weight, as shown by the arrows in the drawing (FIG. 24). In another embodiment, the mold punch 214 may be connected via a hinge 215 to the mold matrix 211, as shown in FIG. 25. The mold punch 214 opens at a predetermined angle, the punch moves as shown by the arrows in the drawing until it closes the cavity inside the mold matrix, and thus molding is performed using the weight of the mold matrix 211 when docked with the mold punch 214 forms.

Although it was mentioned above that in the preferred embodiment, the mold matrix 11 should be made of concrete, perhaps with the same success as using the device in accordance with the invention, also use a conventional device adapted for molding polyurethane foam, if the mold changed in such a way that the margins for trimming are increased and it is possible to expand the molded product by pressing, as shown in Figa and 26b. For example, in a typical installation, parts of the polymer feed (in liquid form) are poured into the cavity, and the upper part 314 of the mold and the lower part 311 of the mold are joined to close the cavity, and the polymers foam in the cavity (foaming is the result of mixing the two polymers). However, the device can be modified as follows: the molded polymer product 30 with a spring structure is placed in the cavity, the product is compressed by joining the two parts of the mold, and the envelope protruding from the joining parts of the mold is removed due to the pressure developed during tight mixing two joined parts of the mold. This makes it possible to obtain a cushioning material 1, as in an embodiment of the present invention, without using a device with concrete abutting parts of the mold. Or, in a preferred embodiment, trim the molded product with a thermal cutter after removing the upper part of the mold. The abutting parts 311, 314 of the mold of a conventional device can be made of metal, for example iron. In a preferred embodiment, the mold is made of concrete or metal, but can also be made of a complex synthetic polymer material, such as fiberglass reinforced plastic (FRP).

As shown in FIGS. 26a and 26b, a portion (e.g., lower mold portion 311) of a conventional device may be used. For example, in accordance with the order of use of a conventional device, parts of the polymer raw material (in liquid form) are poured into the cavity, the upper part of the mold (not shown) and the lower part 311 of the mold are joined, closing the mold, and the polymers in the cavity foam (as a result of mixing two polymers). Instead, the spring-molded polymer product 30 is placed in the device, and can be pressed by joining the mold punch 314 with the bottom part 311 of the mold provided with a base 4 (not shown).

For the compression molding process, ambient temperature or temperature control is important. During the pressing process, parts of the polymer raw material soften and intertwine. This mixing, however, does not occur at the molecular level, since the polymers do not completely melt. In this case, the air masses enclosed in the molded product are the same air that was in the parts of the polymer raw materials. In order to mold the product properly, it is necessary to align the temperature of the air masses with the softening temperature of parts of the polymer raw materials. Otherwise, if the elevated temperature suddenly drops to a much lower level, the air masses will expand, which can cause an elastic reaction that violates the molding if the two parts of the mold are not maintained to maintain equilibrium.

Industrial applicability

According to the description, in accordance with the invention, it is possible to quickly produce a cushioning material containing a molded polymer product with a spring structure, which has the required resistance in relation to the applied weight and impact. Mass production of such a cushioning material is also possible. Since the manufacture of such shock-absorbing materials is based on compression molding, it is possible to easily change the size and shape of individual products. If the shock-absorbing material must be subjected to vertical vibrations, horizontal vibrations or complex vibrations, then on both sides of the shock-absorbing material, bulges and recesses can be made so that the shock-absorbing material can absorb vibrations as best as possible.

In accordance with the method proposed in the present invention, since the flake is simultaneously cut and fused with a thermal cutter that moves along the edges of the mold punch when the two joined parts of the mold are closed, trimming becomes a simple operation. In particular, since trimming is performed at this molding stage, preventing the destruction of open filaments along the edges, thereby making the trimming and stripping operation unnecessary otherwise necessary after pressing, thereby reducing the processing time after pressing.

In addition, since the base to which the molded polymer product with the spring structure is attached also performs the function of a mold punch, to perform the molding, it is only necessary to prepare the mold matrix, which reduces production costs. Further, since the product itself is used as part of a molding device, molding accuracy is improved.

It is possible, when using a molding device comprising a single pair of mating parts of the mold in accordance with the present invention, to produce shock absorbing material, the parts of which differ from each other in thickness. Thus, using the same device, it is possible to produce various shock absorbing materials that differ in size, shape and density, in accordance with individual requirements, without using a variety of pairs of mold parts. In particular, it is possible, if necessary, to produce seats for a particular type of motorcycle, to change the thickness of the seat depending on the type of motorcycle (necessary supporting ability). For example, using the method in accordance with the present invention, it is possible, if necessary, to produce thin shock-absorbing materials, adjust the forming device so that the distance between the two mating parts of the mold is reduced. On the contrary, when it is required to produce thick shock-absorbing materials, it is possible to adjust the forming device so that the distance between the two joined parts of the mold becomes large. Thus, it is possible to produce shock-absorbing material in accordance with an individual order, that is, to make shock-absorbing material that exactly meets the individual requirements of specific customers.

Further, in accordance with the method proposed in the invention, it is possible to easily produce shock absorbing materials that differ in their properties, including thickness, by simply adjusting the interval of movement between the two joined parts of the mold and selecting a suitable material (for example, thread diameter, texture, volume density and void ratio). In particular, in accordance with the method proposed in the invention, it is possible using a single device to produce various shock absorbing materials according to individual requirements, differing in size, shape and density, without resorting to the use of numerous pairs of mold parts. For example, it is possible if you want to make seats for motorcycles or vehicles of a certain type, then seats can be made whose thickness varies depending on the type of motorcycle or vehicle (necessary supporting ability). Moreover, in accordance with the method proposed in the invention, it is possible to produce shock-absorbing materials in which the distribution of spring properties and stiffness can be made by any, simply by changing the interval of movement between two joined parts of the mold, without changing the physical properties of the shock-absorbing material itself. For example, when the shock-absorbing material is used as a motorcycle or vehicle seat, it is possible to change the shock-absorbing material according to the type of motorcycle (for tourism, road racing or motocross) without resorting to any complex technological processes that would otherwise be necessary case. If cushioning material is used as a motorcycle seat material for motocross, it can be made to support the weight of the rider. At the same time, the rider can control the motorcycle while sitting on the seat, which guarantees its stability during riding.

If the cushioning material contains two or more layers, it is possible to easily change the properties of the cushioning material by appropriate selection of its constituted molded polymer products with a spring structure (for example, in relation to the diameter of the threads, material, bulk density, void ratio, etc.) or by adjusting the movement interval between two mating parts of the mold. For example, the distribution of spring properties between the upper layer and the underlying layer can be changed, according to the requirements, without the use of any complex technology: it is enough to simply have a combination of the upper and lower layers with the same spring properties, or to have one stiffness in the upper layer and less rigidity in underlying layer. It is also possible to make such a combination of the upper layers with the underlying layers to form a stepwise change in thickness between adjacent layers to create a central protrusion.

Thus, it is possible to produce seats that can easily meet the specified requirements, for example, compliance with the standards set for the product, functional requirements and individual customer needs, thereby increasing the value of the product. For example, if the cushioning material is used as the seat material of a motorcycle or vehicle, it is possible to change the seat according to the type of motorcycle or vehicle or the anatomical features of the rider. More specifically, if the seat is intended for a motorcycle or motor vehicle for which it is important for the driver (for example, a professional driver) to maintain a certain posture while riding, it is possible to change the seat according to the requirements of the user so that the seat can exactly match the requirements for the driver's posture and features of operation. If cushioning material is used as a motorcycle seat material for motocross, it can be made to support the weight of the rider. At the same time, the rider can control the motorcycle while sitting on the seat, which guarantees its stability during riding.

In accordance with the method proposed in the invention, the manufacture of shock-absorbing materials is simple in comparison with products made of polyurethane foam, which are recycled by conventional methods. In contrast to polyurethane foam, in the manufacture of products from which toxic materials are used, for example, tolylenadiene isocyanate (TDI) and others, a molded polymer product in accordance with the present invention can be manufactured without emission of toxic gases, which provides good working conditions.

In accordance with the method proposed in the invention, polymers such as PE and the like can be processed into thermoplastic polymer edible oil packaging or plastic films biodegradable by microorganisms for use in agriculture, which provides additional benefits. Shock absorbing materials made of a molded polymer product with a spring structure can themselves be subjected to multiple processing with the melting of used shock absorbing materials and the use of melting in the molding process by compression. The molded polymer product in accordance with the present invention is so well suited for repeated processing that it does not pose any environmental burden even if it is to be processed after use. Moreover, the molded polymer product in accordance with the present invention can be manufactured with low manufacturing costs, since recycled polymers can be used for its manufacture.

The inventive cushioning material made of a molded polymer product with a spring structure has high durability and resistance to creasing even after prolonged use, has very little local punching and does not create the feeling of touching a hard bottom or vertical swaying. Moreover, the cushioning material, when the user sits on it, evenly perceives the user's weight over the entire area of contact with the cushioning structure. Therefore, the shock-absorbing material causes less fatigue of the user than pillows made of polyurethane foam, and less stress on the user. Thus, the cushioning material in accordance with the invention creates a specific feeling of lack of tension for the user, which is practically unattainable with a polyurethane foam pillow.

The shock absorbing material in accordance with the invention of a molded polymer product with a spring structure has such good spring properties that when used for the seats of a vehicle or motorcycle, you can do without the use of coil springs, which are installed under the usual seats of vehicles or motorcycles to absorb the reaction from unevenness the surface of the road, causing rider inconvenience. This simplifies the design of the seat, lowers the center of gravity, which helps to stabilize the vehicle or motorcycle when driving.

Since the molded polymer product in accordance with the present invention has a structure with elongated voids, it has such good air permeability that it does not retain moisture. In the event that heated or cooled air is supplied through the pipe from the air conditioner, it can pass through the shock-absorbing material of the motorcycle seat, and the rider can warm or cool while riding. Since the shock-absorbing material is resistant to water and not degradable, when saturated with water, it can be successfully used as a seat material for a motorcycle. The cushioning material can be washed with water, and even then it dries quickly.

As described above, the inventive method of manufacturing a cushioning material from a molded polymer product with a spring structure is successfully used to obtain a cushioning material consisting of a molded polymer product with a spring structure, that is, a material used as any support on which to sit or lying, for example, the seats of motor vehicles, motorcycles, bicycles, electric trains, airplanes, saddles for riding, chairs, sofas and beds, in Depending on whether the seat is exposed to vibrations or not as a substitute for conventional cushion material made of polyurethane foam.

If the shock-absorbing material is used as a support element of the seat, which during operation must be affected by vibrations, then one of the surfaces of the shock-absorbing material must be subjected to compression molding. On the other hand, if the shock-absorbing material is used as a support element of the seat, which during operation can be subjected to intense vibrations, such as the seats of a motor vehicle or a motorcycle, it is desirable that two or more shock-absorbing materials overlap each other, of which each contains a molded polymer spring-loaded product with hanging sides.

If a pantograph jack is used in the extrusion molding device instead of a hydraulic device, the device may have a simpler structure, thereby reducing production costs. In addition, in a device of this design, it is easier to adjust the movement interval between the mating parts of the mold.

Embodiments of the present invention are not limited to the options listed above, but allow a large number of changes and modifications within the technical scope of the claims of the invention. In addition, since certain changes within the scope of the invention may be made in the above construction, it is contemplated that any changes and embodiments equivalent to those described above should be considered to be included within the technical scope of the invention.

Thus, the following claims, reflecting the widest range of claims, are not directed to any device having a specific design, but are intended to protect the essence of the claimed invention. The present invention has novelty and industrial applicability and, as a whole, it is not obvious from the prior art at the time of its creation for a mid-level specialist. Moreover, the present invention is pioneering and has a revolutionary character. Thus, the following claims are subject to the broadest interpretation to provide legal protection for the present invention.

From the above description, it is obvious that the above goals, as well as the goals that obviously follow from the description, are fully achieved. In addition, since some changes can be made in the above construction within the scope of the claims of the invention, it is understood that everything contained in the above description or shown in the attached drawings should be interpreted only as an illustration and not be taken in a restrictive sense.

It is also intended that the following claims cover all the general, particular, and equivalent features of the invention described herein.

Claims (10)

1. The shock-absorbing material from the molded polymer product having a structure with spring properties, which is a three-dimensional structure with voids and a given bulk density, including a single-layer structure or obtained by applying two or more layers having the same or different spring properties, characterized in that the three-dimensional the structure is formed by introducing into contact, twisting and collecting adjacent randomly located loops or spirals of continuous and / or hollow continuous yarns and / or short yarns obtained from a thermoplastic polymer, is heated in a mold punch that contains a base that is part of the mold and inserted into the die for the stroke length of the punch, or in the mold matrix to a temperature sufficient to soften the three-dimensional structure, then it is compressed to a thickness corresponding to the stroke length of the punch and cured by cooling. 2. The cushioning material according to claim 1, characterized in that the springy properties of the molded polymer product are determined by the density, material and / or diameter of the threads of the three-dimensional structure. 3. A cushioning material from a molded polymer product having a spring-loaded structure, comprising a three-dimensional structure consisting of contiguous, twisted and assembled adjacent randomly arranged loops or spirals of continuous and / or hollow continuous threads and / or short threads obtained from a thermoplastic polymer, and having on its upper and lower surfaces at least two bulges formed on predetermined linear regions by means of a thread of a thermoplastic polymer, I sew her each region and shortened edge pressure. 4. A method of manufacturing a cushioning material from a molded polymer product having a structure with spring properties, in which a three-dimensional structure is formed with voids and a given bulk density by contacting, twisting and collecting adjacent randomly located loops or spirals of continuous and / or hollow continuous and / or short filaments obtained from a thermoplastic polymer, then a three-dimensional structure is placed in the matrix, the mold punch or the mold is heated forms and / or three-dimensional structure to a temperature sufficient to soften the three-dimensional structure, characterized in that they establish mutual movement of the joined parts of the mold, that is, the mold punch and the mold matrix, to the desired thickness of the cushioning material, then compress the three-dimensional structure to the required thickness of the cushioning material, after which the three-dimensional structure is cured by cooling, while the three-dimensional structure includes a single-layer structure or obtained by applying two and or more layers having identical or different properties. 5. The method according to claim 4, characterized in that of the two joined parts of the mold, at least the mold matrix is made of concrete. 6. The method according to claim 4, characterized in that the excess edges are cut off with a thermal cutter protruding from the three-dimensional structure into the gap between the two joined parts of the mold and the open ends of the threads are fused together at the edges. 7. The method according to claim 4, characterized in that the vertical movement of at least one of the two mating parts of the mold is carried out by means of a jack-type pantograph. 8. The method according to claim 4, characterized in that the mold matrix is made by pouring concrete mass into the space inside the frame made by the reference mold matrix, suitable for molding a polymer product having a structure with spring properties, after which allow the aforementioned harden the concrete mass. 9. A method of manufacturing a cushioning material from a molded polymer product having a structure with spring properties, in which the melt of the thermoplastic polymer is extruded into yarns and brought into contact, twisted and assembled randomly arranged loops or spirals of continuous threads to form a three-dimensional structure with voids and a given bulk density, then cut off the edges of the three-dimensional structure forming a molded polymer product having a structure with spring properties E, to yield U-shaped or V-shaped profile, and edge sewn thread obtained from a thermoplastic polymer, and crosslinked thermoplastic polymer filament edge of predetermined linear areas on the top and bottom surfaces of the three-dimensional structure and shorten the yarn pressure. 10. The method according to claim 9, characterized in that the three-dimensional structure is placed in the mold matrix, the mold matrix and / or the three-dimensional structure are heated to a temperature sufficient to soften the structure, the three-dimensional structure is compressed by pressing the mold punch into the matrix molds with a tight contact between them, cool the three-dimensional structure with constant springing properties and sew the edges of the thermoplastic polymer into the predetermined linear regions on the upper and lower surfaces three-dimensional structure with the subsequent shortening of the thread pressure.

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