WO2010109311A2 - Ensemble cadre et panneau de tissu - Google Patents

Ensemble cadre et panneau de tissu Download PDF

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Publication number
WO2010109311A2
WO2010109311A2 PCT/IB2010/000667 IB2010000667W WO2010109311A2 WO 2010109311 A2 WO2010109311 A2 WO 2010109311A2 IB 2010000667 W IB2010000667 W IB 2010000667W WO 2010109311 A2 WO2010109311 A2 WO 2010109311A2
Authority
WO
WIPO (PCT)
Prior art keywords
frame
fabric panel
resin
fabric
mould
Prior art date
Application number
PCT/IB2010/000667
Other languages
English (en)
Other versions
WO2010109311A3 (fr
Inventor
Stephanus Bekker
Gustav Johann Van Der Merwe
Original Assignee
Aat Composites (Pty) Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Aat Composites (Pty) Ltd filed Critical Aat Composites (Pty) Ltd
Publication of WO2010109311A2 publication Critical patent/WO2010109311A2/fr
Publication of WO2010109311A3 publication Critical patent/WO2010109311A3/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
    • B60N2/68—Seat frames
    • B60N2/686—Panel like structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/56—Tensioning reinforcements before or during shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
    • B29C70/76—Moulding on edges or extremities of the preformed part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
    • B60N2/68—Seat frames
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
    • B60N2/70—Upholstery springs ; Upholstery
    • B60N2/7011—Upholstery springs ; Upholstery of substantially two-dimensional shape, e.g. hammock-like, plastic shells, fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/771—Seats

Definitions

  • This invention relates to a frame and fabric panel assembly in which opposite edges or ends of a fabric panel, that may assume the form of webbing, are permanently secured to opposite frame members of a fibre reinforced resin frame that is typically a component of a seat and backrest assembly.
  • the invention relates to frame and fabric panel assemblies of the general type in which the frame is a thermoset or thermoplastic composite tubular frame that, for example, may be used in the seat of a transport vehicle, especially an aircraft.
  • the fabric panel typically provides support for a seated person but may also simply close the space between two opposite frame members.
  • the invention also relates to a process for the production of a fibre reinforced structure having a fabric panel, especially a pre-tensioned fabric panel, permanently secured to it.
  • thermoset and thermoplastic composite frames having opposite ends or edges of fabric panels permanently secured to opposite frame members are used in vehicle and aircraft seat assemblies, for example.
  • Such fabric panels typically provide lumbar support for mostly ergonomic reasons to provide comfort to a passenger while seated.
  • the fabric panel also reduces the amount of cushioning required on, for example, a backrest.
  • the permanent securing of the ends or edges of a fabric panel to such a frame in an effective manner is, however, problematic in a production facility. It has become common practice to use an aluminium or composite structure in which loop and pile fastener components such as those sold under the trade name VELCROTM and grooved slots are used to fasten the fabric panel to the frame. This, however, involves more than one production step and the use of various fasteners thereby adding to the cost of labour as well as of components.
  • a frame and fabric panel assembly comprising a fibre reinforced synthetic resin frame to which at least one fabric panel is permanently secured, the assembly being characterised in that appropriate areas of the fabric panel are secured to the frame by at least partially embedding such appropriate areas of the fabric in synthetic resin that is chemically bonded to the synthetic resin of the frame in order to form said permanent bond.
  • the fabric panel to be a dry woven type of material, particularly a type that is often referred to as webbing; for the appropriate areas to be at least a pair of opposite edge or end regions of the fabric panel; for the fabric panel to be under a predetermined tension in the installed condition; for the said appropriate areas to be secured to a surface of the frame by resin that bonds to the resin of the frame with the option that the appropriate areas may be sandwiched between such a surface of the frame and a fibre reinforced overlay covering said appropriate areas; for the fabric panel to be secured to surfaces of the frame that are generally coplanar with the panel in the installed condition in which instance a reinforcing strip may be attached to the fabric panel and to another surface of the frame with the attachment of the reinforcing strip to the fabric panel being by way of stitching or adhesive, or preferably both; for the fibres in the fibre reinforced composite structure to be carbon or glass fibres; for the resin to be either a thermosetting resin or a thermoplastic resin; and for the assembly to be a component
  • Production of an assembly defined above may be achieved by securing the appropriate areas of a fabric panel to a fibre reinforced synthetic resin frame after the latter has been manufactured.
  • the securing of the appropriate areas of the fabric panel to a fibre reinforced synthetic resin frame be carried out during production of the frame itself.
  • a process for the production of a fibre reinforced frame and fabric panel assembly comprising the steps of applying one or more layers of woven or nonwoven fibre reinforcing material and uncured resin to a prepared mould surface to form an uncured fibre reinforced frame having at least a partially exposed outer surface; the process being characterised in that a fabric panel is tensioned in a position over spaced appropriate areas to be attached to the frame that form part of the partially exposed outer surface; ensuring the provision of sufficient uncured resin to at least partially embed said appropriate areas of the fabric panel in uncured resin; closing the mould cavity; causing or allowing the resin to cure to thereby cause the frame to cure whilst permanently securing the appropriate areas of the fabric panel to the frame; and opening the mould and removing the moulded fibre reinforced frame therefrom together with the permanently attached fabric panel.
  • the frame to be of tubular shape in which instance said one or more layers of fibre reinforcing material and uncured resin are closed to form a tubular configuration around an inflatable bladder; for the mould to be partially closed by clamping top and bottom parts of a mould together to simultaneously clamp the fabric panel to the mould in a tensioned condition, preferably by engaging the fabric panel on the inside of the relevant frame member in which instance excess fabric of the fabric panel can be trimmed away followed by final closing of the mould and inflating of any bladder that may be present preparatory to curing of the resin; for the exact tensioning of the fabric panel to be carried out with the aim of providing optimum comfort and support; for curing to be effected at an elevated temperature; and for additional pressure to be applied either to the internal or external surfaces of the composite lay up.
  • Still further features of the invention provide for a plurality of different fabric panels to be secured to a frame to span different areas of the frame with each fabric panel optionally being differently tensioned; for the fibre reinforcing material and uncured resin to be in the form of sheets of fabric reinforcing made of reinforcing fibres that are pre-impregnated with the necessary resin, typically epoxy or phenolic resin, that is sufficient to form the fibre reinforced composite simply by heating whilst applying pressure; and for the fabric panels to be positioned and fixed in such a way as to prevent resin from reaching specific areas of the fabric panel.
  • the necessary resin typically epoxy or phenolic resin
  • Figure 1 illustrates schematically an example of a fibre reinforced composite frame such as is used as an airline seat backrest, the frame having a plurality of fabric panels permanently secured to it;
  • Figure 2 illustrates schematically an open mould with the exposed mould surfaces
  • Figure 3 illustrates schematically the assembly of the mould sides to completely enclose the fibre reinforced matrix after fibre placement and prior to pressurisation
  • Figure 4 illustrates schematically the assembled mould
  • Figure 5 is a schematic section taken through one alternative in which the fabric panel is simply secured on top of one of the surfaces of the tubular composite frame.
  • Figure 6 is the same as Figure 5 but showing additional layers of woven or nonwoven fibre reinforcing material placed as an overlay on top of the edge of the fabric panel to sandwich it between the overlay and appropriate areas of the tubular frame as well as an optional reinforcing strip;
  • Figure 7 illustrates schematically the initial step in the production of an assembly such as is illustrated in Figure 6;
  • Figure 8 illustrates, in lesser detail, an intermediate step in the production of the assembly illustrated in Figure 6;
  • Figure 9 illustrates the final step in which the mould is finally closed and without specifically illustrating the reinforcing strip.
  • a typical inverted U-shaped tubular fibre reinforced article in the form of a tubular composite frame (1), illustrated in Figure 1 is made using the preferred method of the invention, the frame being that of a backrest of an aircraft or other transport vehicle seat.
  • a tubular frame generally follows an ergonomic contour, insofar as its general plane is concerned, and may vary along its length in its cross-sectional size and shape according to well-developed designs.
  • the cross-sectional shape is illustrated as being a simple rectangular shape.
  • the lumbar region of the frame has a fabric panel (2) secured to opposite sides of the frame and, as indicated above, this fabric panel is secured to the tubular composite frame during the manufacture thereof.
  • the fabric panel may be a single fabric panel but in this embodiment of the invention is a plurality of different juxtaposed fabric panels located one above the other in which instance they may be tensioned differently according to particular designs and requirements. Also, as the manufacture of the tubular composite frames takes place according to applicant's own technology, the manufacture of the frame itself is also described below for purposes of completeness.
  • the composite frame is produced utilising sheets of fabric reinforcing made of reinforcing fibres that are pre-impregnated with the necessary resin, typically epoxy or phenolic resin, that is sufficient to form the fibre reinforced composite simply by heating whilst applying pressure, as will be described further below.
  • the necessary resin typically epoxy or phenolic resin
  • Such pre-impregnated sheets are often referred to in the industry as prepregs and have the advantage that exactly the correct quantity of resin is pre-applied to the sheets of reinforcing fibres at factory level where control is much easier than in an on-site application where layering takes place without serious control of the amount of resin used. Using pre-impregnated sheets therefore avoids the use of too little or too much resin.
  • the placement of the pre-cut, preimpregnated sheets is illustrated schematically in Figure 7 from which it can be seen that the open mould, for the purposes of placement of the sheets of reinforcing material, is of generally outwardly directed angle shape.
  • the edges of the sheets project outwards from the mould surfaces sufficiently to enable them to be folded over in order to close the tubular configuration of the frame with a tubular inflatable bladder (5) enveloped in the uncured tubular frame.
  • the mould in this instance, consists of a main bottom part (6), a top part (7), and removable sides (8).
  • the top part and bottom part together form an outwardly directed channel shape of the mould when they are engaged with each other as illustrated in Figure 8 and the removable sides close the entire mould cavity as illustrated in Figure 9.
  • the fabric panel (2) or individual parts thereof is or are stretched to the required tension across the bottom part of the mould, with the uncured frame already prepared.
  • the top part of the mould is then clamped onto the bottom part in order to hold the fabric panel in tension.
  • a somewhat resilient clamping bead (9) is provided in the top mould part to ensure effective clamping and retention of the required tension in the fabric panel.
  • the clamping bead also serves to prevent resin from reaching areas of the fabric panel between the frame members that may create a hard and uncomfortable feel to parts of the fabric panel.
  • the top part of the mould also has a rebate (10) to accommodate an overlay (11) of pre-cut pre-impregnated sheets of reinforcing material in order to sandwich the appropriate areas of the fabric panel between the surface of the frame and the overlay.
  • a reinforcing strip (15) may be attached to the fabric panel so that it becomes located adjacent the frame in the installed condition and passes through a right angle in section so that approximately one half of the width of the reinforcing strip is attached to the side surface (16) of the frame, this attachment being by way of the resin in the manner described above.
  • attachment of the other half to the reinforcing strip to the fabric panel is preferably by way of both adhesive indicated by numeral (17) and at least one line of stitching indicated by numeral (18).
  • the adhesive may be different from the resin and may be somewhat flexible so that it can act as a seal between the surfaces of the mould to positively prevent any resin from permeating along the fabric panel.
  • the clamping bead (9) may prove to be unnecessary.
  • the reinforcing strip serves to inhibit the fabric panel from pulling away from the frame in a direction at right angles to the plane of the panel.
  • the sides (8) of the mould are then positioned and secured in place in such a fashion as to resist internal pressure applied to the material by the bladder when it is inflated and to define a closed passage enabling a tubular shape to be moulded against the composite duct shaped mould surface defined by the main bottom part, top part and removable sides.
  • inlet nozzles (12) are provided for supplying compressed air to the bladder (5) in order to inflate it and maintain it in an inflated condition whilst the synthetic resin cures under elevated temperature.
  • the bladder in operation, is thus pressurized, as is well known in the art, to form and compact the material onto the mould surface and hold it there during the curing process. Accordingly, the bladder together with positive pressure holds the layers firmly in position in the mould during the curing process and assists in ply compaction. Curing may be aided or induced in any manner that is appropriate to the particular resin being used but would typically involve the use of heat.
  • resin penetrates the thickness of the appropriate areas of the fabric panel and becomes fully cured to bond the fabric panel permanently to the moulded frame. It is to be noted that the uncured resin acts as a strong adhesive to bond the fabric panel to the composite material preparatory to and during the curing process. If it is required, of course, additional resin can be added to appropriate areas of the fabric in order to ensure that the fabric becomes properly embedded in resin that becomes one continuous mass with the resin of the frame itself and that of the overlay.
  • both the sides and top of the mould are removed in order to facilitate removal of the moulded frame together with its permanently attached fabric panel.
  • the bladder is removed from the interior of the tubular frame in the usual manner.
  • the cross-sectional shape of the frame may vary widely and the frame may not be tubular but could be of some other suitable cross-section such as a channel shape, an angle shape, or even that of a solid cross-section such as a bar or rod. In such an instance the use of any bladder or bagging film is obviated.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Transportation (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Seats For Vehicles (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

La présente invention concerne un ensemble cadre et panneau de tissu comprenant un cadre en résine synthétique renforcé par des fibres (1) auquel est fixé de façon permanente au moins un panneau de tissu (2). Des zones appropriées du panneau de tissu sont fixées au cadre en intégrant au moins en partie ces zones appropriées du tissu dans de la résine synthétique qui est chimiquement liée à la résine synthétique du cadre afin de former ladite liaison permanente. La présente invention concerne également un procédé de fabrication de l'ensemble, comprenant les étapes consistant à appliquer une ou plusieurs couches (4) de matériau de renforcement en fibre tissée ou non tissée et de résine non polymérisée à la surface préparée d'un moule (3) pour former un cadre renforcé par des fibres non polymérisées ayant au moins une surface externe partiellement exposée. Le panneau de tissu est tendu dans une position au-dessus des zones appropriées espacées de la surface externe exposée. La quantité de résine non polymérisée est suffisante pour assurer au moins l'incorporation partielle desdites zones appropriées du panneau de tissu dans la résine non polymérisée. La cavité du moule est fermée et la résine peut être polymérisée pour fixer de façon permanente les zones appropriées du panneau de tissu au cadre.
PCT/IB2010/000667 2009-03-26 2010-03-25 Ensemble cadre et panneau de tissu WO2010109311A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ZA200902176 2009-03-26
ZA2009/02176 2009-03-26

Publications (2)

Publication Number Publication Date
WO2010109311A2 true WO2010109311A2 (fr) 2010-09-30
WO2010109311A3 WO2010109311A3 (fr) 2011-01-06

Family

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Application Number Title Priority Date Filing Date
PCT/IB2010/000667 WO2010109311A2 (fr) 2009-03-26 2010-03-25 Ensemble cadre et panneau de tissu

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Country Link
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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013230787A (ja) * 2012-05-01 2013-11-14 Toyota Boshoku Corp 車両用シート
ITMI20131364A1 (it) * 2013-08-08 2015-02-09 Sparco S P A Metodo per produzione di un prodotto composito che prevede una matrice polimerica presentante fibre di rinforzo, e prodotto ottenuto con tale metodo
DE102013223835A1 (de) * 2013-09-05 2015-03-05 Johnson Controls Components Gmbh & Co. Kg Composite-Bauteil, insbesondere für einen Fahzeugsitz, und Fahrzeugsitz

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1985003420A1 (fr) * 1982-07-22 1985-08-15 Etablissements M. Duret & Fils S.A. Procede pour la realisation d'un element de siege par le moulage d'un cadre sur une garniture et element de siege obtenu par ledit procede
WO2009016609A1 (fr) * 2007-08-01 2009-02-05 Selle Royal S.P.A. Support de corps humain élastique et son procédé de réalisation

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1985003420A1 (fr) * 1982-07-22 1985-08-15 Etablissements M. Duret & Fils S.A. Procede pour la realisation d'un element de siege par le moulage d'un cadre sur une garniture et element de siege obtenu par ledit procede
WO2009016609A1 (fr) * 2007-08-01 2009-02-05 Selle Royal S.P.A. Support de corps humain élastique et son procédé de réalisation

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013230787A (ja) * 2012-05-01 2013-11-14 Toyota Boshoku Corp 車両用シート
ITMI20131364A1 (it) * 2013-08-08 2015-02-09 Sparco S P A Metodo per produzione di un prodotto composito che prevede una matrice polimerica presentante fibre di rinforzo, e prodotto ottenuto con tale metodo
DE102013223835A1 (de) * 2013-09-05 2015-03-05 Johnson Controls Components Gmbh & Co. Kg Composite-Bauteil, insbesondere für einen Fahzeugsitz, und Fahrzeugsitz
US10322655B2 (en) 2013-09-05 2019-06-18 Johnson Controls Components Gmbh & Co. Kg Composite component for a vehicle seat, and vehicle seat

Also Published As

Publication number Publication date
WO2010109311A3 (fr) 2011-01-06

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