WO2012009417A1 - Système et procédé pour former des matériaux de siège à densité variable - Google Patents

Système et procédé pour former des matériaux de siège à densité variable Download PDF

Info

Publication number
WO2012009417A1
WO2012009417A1 PCT/US2011/043825 US2011043825W WO2012009417A1 WO 2012009417 A1 WO2012009417 A1 WO 2012009417A1 US 2011043825 W US2011043825 W US 2011043825W WO 2012009417 A1 WO2012009417 A1 WO 2012009417A1
Authority
WO
WIPO (PCT)
Prior art keywords
foam material
mold
moveable member
uncured foam
uncured
Prior art date
Application number
PCT/US2011/043825
Other languages
English (en)
Inventor
Ryoko Yamasaki
Brent T. Hodge
William W. Li
Original Assignee
Johnson Controls Technology Company
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 Johnson Controls Technology Company filed Critical Johnson Controls Technology Company
Priority to CA2804637A priority Critical patent/CA2804637C/fr
Priority to US13/806,664 priority patent/US20130125313A1/en
Priority to JP2013519789A priority patent/JP5868400B2/ja
Priority to CN201180034315.2A priority patent/CN102985248B/zh
Priority to KR1020137003567A priority patent/KR101450027B1/ko
Priority to EP11807439.2A priority patent/EP2593293A4/fr
Publication of WO2012009417A1 publication Critical patent/WO2012009417A1/fr

Links

Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C7/00—Parts, details, or accessories of chairs or stools
    • A47C7/02—Seat parts
    • A47C7/021—Detachable or loose seat cushions
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B29C44/0446—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities by increasing the density locally by compressing part of the foam while still in the mould
    • 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
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00

Definitions

  • the present invention generally relates to a system and method of forming seating materials having a variable density gradient and more specifically to forming foam materials for vehicle seats having a variable density gradient that allow greater comfort across a wider range of occupant weights, and the use of single foam formulations across a wide range of types of vehicle seats having significantly different desired performance characteristics.
  • Vehicle manufacturers must make their vehicle seats comfortable to a wide range of vehicle occupants having significantly different weights and sizes.
  • the manufacturer of a vehicle seat must consider a weight range from that of a small child who no longer needs a booster seat through the upper weight and size range of adults.
  • a lighter occupant and a heavier occupant would find the same vehicle seat to perform significantly different, and each occupant would prefer very different hardness and more specifically the amount of deflection of seating materials.
  • the static comfort of a seating foam such as a polyurethane seating foam, depends greatly on the hardness and density of the foam, especially at high deflection.
  • a harder foam generally ensures a comfortable seating material for a heavy occupant, but also results in less deflection, which causes lighter occupants to find the seat not comfortable, such as the seat being too hard, causing them to sit on top of the foam, and not sink, at least partially, into the foam. While manufacturers may adjust the hardness of the foam to that preferred by an average user, the more displaced the vehicle occupant is in weight from the average user, the less comfortable they find the vehicle seat. Therefore, in a single material, a single piece of foam construction seat, to date manufactures are limited in their ability to provide a comfortable seating surface for a wide range of occupant weights.
  • the variance in comfort of seating materials or desired performance of seating materials may also vary depending on the desired application, vehicle type, target consumer, and vehicle manufacturer preferences. For example, in many sport or performance cars, it is desirable to have a firmer seat than in luxury cars.
  • the two-part seat material may be formed by two methods. The first is to generally apply a separately soft layer of foam to a harder molded foam wherein the soft slab of foam is closest to the A surface or seating surface of the seat material. In such a method of forming a two-part foam seating material, first the harder foam seat material is molded and then a second softer seat material is molded or cut from slabstock foam with the desired shape. Then the two parts are glued together with an adhesive, which increases production costs significantly due to the extra labor, equipment, materials and space needed.
  • the use of an adhesive to glue the soft die cut slabstock foam or separately molded piece to the harder molded foam is generally not desirable.
  • the adhesive may make it more difficult to recycle the seat at the end of the life cycle and it is difficult to find environmentally friendly adhesives with desired performance characteristics over the life cycle of the seat.
  • the second method some seating manufacturers have also developed is a mold-in process to form a two-part seating material that eliminates the need for the adhesive. Even though the need for the adhesive is eliminated, significant disadvantages also occur in the molding process that significantly slow the line speed and processing time for each seating material. More specifically, many manufacturers use a method of foam production that pours multiple formulations within one mold, typically in layers to achieve high hardness bolsters while maintaining a softer insert near the A surface. The additional formulations and processing steps require additional space to store the different components that are used in the mold, additional equipment space, and additional demands are placed on the operators of the manufacturing process. Furthermore, no suitable technology has been found to date to prevent contamination of the mold-in slab from the liquid polyurethane chemical blends mixing during foaming process.
  • the present invention generally relates to a system and method of forming seating materials having variable density gradient for high hardness ratio of high-to-low deflection. More specifically to forming foam materials for vehicle seats having variable density gradient that allow greater comfort across a wider range of occupant weights.
  • the present invention uses a method to create a variable hardness seating material with only minimal tooling changes and limited to no reduction in manufacturing efficiency.
  • the material is placed in a mold and then expanded to fill the mold.
  • the present invention uses molds that have larger cavity areas in which moveable plates or mold sections rest. With the mold cavities filled with the expanded foam and approaching the cured state, the moveable plate compresses the seat to the final size, such that the areas closest to the moveable plate are compressed to have greater densities. This creates a variable density seat with greater differential in hardness between low and high deflections.
  • the seat foam is more comfortable to a wide range of occupant weights, deflecting as desired for the lighter weight occupants while providing sufficient support for heavier occupants in order to prevent the sensation known as "bottoming out.”
  • FIG. 1 illustrates an exemplary seating mold with an A surface being on the bottom side and the initial location of the mold materials after the mold of the present invention is closed;
  • FIG. 2 illustrates the mold in FIG. 1 with the foam seating material expanded to completely fill the mold cavity and a moveable plate in a first position
  • FIG. 3 illustrates the mold of FIG. 2 wherein the moveable plate has moved from the first position to a second position, which compresses the seating material providing the illustrated increased density gradient on the backside of the seating material;
  • FIG. 4 illustrates an exemplary graph of strain in millimeters relative to an applied force to the seating material of the present invention compared to that of a conventional seating material;
  • FIG. 5 illustrates an exemplary graph of frequency versus transmissibility using the same formulation, density and thickness wherein transmissibility has the same formulation density and thickness;
  • FIG. 6 illustrates deflection versus hardness with the same formulation, thickness and weight
  • FIG. 7 illustrates an exemplary graph of a load deflection curve with the deflector percentage versus force and more specifically illustrating that a similar load deflection curve may be obtained using a foam that is only 70 mm and 1 ,096 g versus conventional foam that is 96 mm and 1,220 g.
  • the present invention generally relates to a system and method of forming a seat (not illustrated).
  • the seat generally includes a seating material that provides support to the vehicle occupant, such as the illustrated foam base 10.
  • the foam base 10 includes an A surface 12, a back surface 13 and bolsters 18.
  • the cross sectional view shows a density gradient area 14, having a higher density area 15 and a lower density area 16 in the final foam base 10 configuration.
  • the seat is generally formed in a mold. While the seat material, in particular the foam base 10, may be formed in any style, size, or configuration, the Figures show an exemplary seat and the present invention is applicable to other styles and configurations.
  • the mold 20 would vary in style, shape, size, and configuration as desired to form the particular desired seating material and in addition to the illustrated foam base 10.
  • the mold 20 generally includes a base 24 and sidewalls 26 into which the foam material is placed for the mold process to begin.
  • the illustrated mold 20 generally includes bolster cavities 28 and a main cavity 30 which are confined by the sidewalls 26, base 24, and an upper plate 32. As illustrated in FIG. 2, the upper plate 32 may have a first or retracted position 34, and as further illustrated in FIG.
  • the illustrated mold 20 is for forming a base 10 of a seat and different molds may be used for different styles, shapes, sizes and configurations, as well as different molds to be required for the seating materials for the upper back of a seat, or for example, a rear seat of a vehicle.
  • other portions of the mold may include additional moveable plates to vary the density of other portions of the seat such as a moveable plate in the bolster area (not illustrated) to provide different densities in the bolster area.
  • the present invention and in particular the process of forming the seat, starts similar to other seat forming processes in that the mold is open and a mold material such as a polyurethane seating foam initial material is placed or inserted in the mold in desired quantities and then the mold is closed.
  • the mold depending upon the type of material used, may be preheated to a desired temperature before the material is placed into the mold.
  • the material 11 may be any type of material commonly used or desirable for use in forming the seating structure.
  • the present invention as illustrated in FIG. 4 compares a conventional polyurethane foam seat base to a polyurethane foam seat base that incorporates the present invention.
  • the process of expanding the foam to fill the mold starts as illustrated in FIG. 2. More specifically, the material in FIG. 2 has filled the mold and has reached a state of semi- cure and normally would be allowed to stay in the mold without change for some additional specified time period.
  • the mold 20 of the present invention includes an enlarged cavity area such as the illustrated main cavity 30 wherein in the initial position as illustrated in FIG. 2 the foam fills a greater area than desired for the final seat base 10 as illustrated in FIG. 3.
  • the inner plate 32 is moved from the first position 34 as illustrated in FIG. 2 to the second position 36 as illustrated in FIG. 3.
  • the mold cavity forms the final desired shape and size of the seat base 10.
  • the area closest to the upper plate 32 of the foam base 10 has the highest density area 15.
  • the lowest density area 16 is furthest away from the upper plate 32 and is approximately the A surface 12 which is engaged against the A mold surface 24.
  • the density of the foam in the main cavity 30 may vary on a gradual even density gradient but is expected that the increase in density is more of an exponential nature than a linear nature. More specifically, the lower density area 16 extends further into the foam base 10 and as it approaches the back surface 13, the density substantially increases quickly to the high density area 15. As the graph illustrates in FIG.
  • the present invention allows for low hardness at low deflection and then increased hardness at a higher rate than a conventional seat foam as the deflection increases.
  • the present invention as illustrated in FIG. 4 provides a better static comfort for a wider range of occupant weights while eliminating expensive two-part foam seating materials.
  • the present invention may use less material and have less overall mass by providing high density in only the sections where needed.
  • the mold 20 is only one style of a particular foam base 10, and other styles may be used which in addition include other areas that include moveable plates in addition to the illustrated upper plate or in place of the upper plate, such that the density gradient could have greater adjustment to particular seat styles, shapes or configurations allowing for the complete tailoring of a particular seat for the most comfortable possible position.
  • the cavity of the bolster cavity 28 could be intentionally enlarged and include a moveable bolster plate (not illustrated) that increases the density on the outer boundaries of the bolsters to provide more support when needed.
  • the moveable plate may not have uniform compression along the length of the upper back (not illustrated). Therefore, it is possible through using multiple plates across a surface to create various density gradients where desired to increase seating comfort.
  • a seating base such as the illustrated foam base 10
  • the front where less weight is placed by the legs, would have a softer, more comfortable seating position, while the seat would allow greater support in the foam base where the most weight is placed by a particular user. This would increase seating comfort and reduce fatigue of the vehicle operator.

Landscapes

  • Physics & Mathematics (AREA)
  • Health & Medical Sciences (AREA)
  • Oral & Maxillofacial Surgery (AREA)
  • Thermal Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Seats For Vehicles (AREA)

Abstract

L'invention concerne un système et un procédé pour former des matériaux de siège à gradient de densité variable pour un haut différentiel de dureté entre flexions élevée et faible, et plus particulièrement pour former des matériaux en mousse pour sièges de véhicule présentant un gradient de densité variable qui permet d'obtenir un confort plus grand pour une plus large gamme de poids d'occupant, ainsi que l'utilisation de formulations de mousses uniques dans une vaste gamme de types de sièges de véhicule présentant différentes caractéristiques de performance souhaitées.
PCT/US2011/043825 2010-07-13 2011-07-13 Système et procédé pour former des matériaux de siège à densité variable WO2012009417A1 (fr)

Priority Applications (6)

Application Number Priority Date Filing Date Title
CA2804637A CA2804637C (fr) 2010-07-13 2011-07-13 Systeme et procede pour former des materiaux de siege a densite variable
US13/806,664 US20130125313A1 (en) 2010-07-13 2011-07-13 System And Method Of Forming Variable Density Seating Materials
JP2013519789A JP5868400B2 (ja) 2010-07-13 2011-07-13 座席クッションを形成する方法
CN201180034315.2A CN102985248B (zh) 2010-07-13 2011-07-13 形成可变密度座椅材料的系统和方法
KR1020137003567A KR101450027B1 (ko) 2010-07-13 2011-07-13 가변 밀도 시팅 재료를 형성하는 시스템 및 장치
EP11807439.2A EP2593293A4 (fr) 2010-07-13 2011-07-13 Système et procédé pour former des matériaux de siège à densité variable

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US36382010P 2010-07-13 2010-07-13
US61/363,820 2010-07-13

Publications (1)

Publication Number Publication Date
WO2012009417A1 true WO2012009417A1 (fr) 2012-01-19

Family

ID=45469788

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2011/043825 WO2012009417A1 (fr) 2010-07-13 2011-07-13 Système et procédé pour former des matériaux de siège à densité variable

Country Status (7)

Country Link
US (1) US20130125313A1 (fr)
EP (1) EP2593293A4 (fr)
JP (1) JP5868400B2 (fr)
KR (1) KR101450027B1 (fr)
CN (1) CN102985248B (fr)
CA (1) CA2804637C (fr)
WO (1) WO2012009417A1 (fr)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP4932664B2 (ja) * 2007-10-16 2012-05-16 株式会社フジクラ 光ファイバ及び一心双方向光送受信モジュール
EP2887837A4 (fr) 2012-08-23 2016-04-20 Lear Corp Système de siège pour offrir un confort à la région thoracique
CN104582535B (zh) 2012-08-23 2018-02-13 李尔公司 胸区舒适就坐系统
US9282785B2 (en) * 2013-03-15 2016-03-15 New Balance Athletic Shoe, Inc. Multi-density sole elements, and systems and methods for manufacturing same
JP6600134B2 (ja) * 2014-11-25 2019-10-30 株式会社東洋クオリティワン クッションパッド
US10457175B2 (en) * 2017-08-15 2019-10-29 GM Global Technology Operations LLC Cushion with spatially varying lattice structures

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3658972A (en) 1970-05-28 1972-04-25 Olin Corp Process for molding a multiple density polyurethane foamed product
US4374885A (en) * 1980-01-23 1983-02-22 Ikeda Bussan Co., Ltd. Cushion materials and method of making same
US5850645A (en) * 1995-07-24 1998-12-22 Ogawa; Taro Multi-layer seat having different hardness and method for manufacturing the same
US6226819B1 (en) * 1996-07-12 2001-05-08 Namba Press Works., Ltd. Multi-layered seat having different hardnesses and provided with skin, and process of manufacturing the same
US6358445B1 (en) * 1996-12-10 2002-03-19 The Dow Chemical Company Process for manufacturing multilayered foam articles

Family Cites Families (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3718417A (en) * 1971-04-09 1973-02-27 Uniroyal Inc Apparatus for molding foam articles
JPS50101585U (fr) * 1974-01-30 1975-08-22
JPS51103973A (fr) * 1975-03-10 1976-09-14 Wako Chem
JPS5799912A (en) * 1980-12-12 1982-06-21 Ikeda Bussan Co Cushion material and production thereof
JPS6120727A (ja) * 1984-07-09 1986-01-29 Nissan Motor Co Ltd 発泡成形方法
JP2909112B2 (ja) * 1989-11-30 1999-06-23 日本発条株式会社 クッション材の製造方法
EP0765722A1 (fr) * 1995-09-28 1997-04-02 Siebolt Hettinga Procédé de contrÔle d'épaisseur de la peau d'un article plastique de densité contrÔlé
JP3769681B2 (ja) * 1999-03-24 2006-04-26 三菱電機株式会社 発泡成型材の製造方法
KR100314431B1 (ko) * 1999-04-23 2001-11-15 구자홍 진공단열재 코어의 제조방법
EP2185334B1 (fr) * 2007-08-27 2020-04-29 DDP Specialty Electronic Materials US, Inc. Procédé amélioré de formation de mousses de polystyrène extrudé et produits ainsi obtenus
DE202009002230U1 (de) * 2009-02-16 2010-04-15 Roche, Peter Polyurethanelastomere

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3658972A (en) 1970-05-28 1972-04-25 Olin Corp Process for molding a multiple density polyurethane foamed product
US4374885A (en) * 1980-01-23 1983-02-22 Ikeda Bussan Co., Ltd. Cushion materials and method of making same
US5850645A (en) * 1995-07-24 1998-12-22 Ogawa; Taro Multi-layer seat having different hardness and method for manufacturing the same
US6226819B1 (en) * 1996-07-12 2001-05-08 Namba Press Works., Ltd. Multi-layered seat having different hardnesses and provided with skin, and process of manufacturing the same
US6358445B1 (en) * 1996-12-10 2002-03-19 The Dow Chemical Company Process for manufacturing multilayered foam articles

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of EP2593293A4 *

Also Published As

Publication number Publication date
KR101450027B1 (ko) 2014-10-13
CN102985248A (zh) 2013-03-20
JP2013537491A (ja) 2013-10-03
KR20130029443A (ko) 2013-03-22
CN102985248B (zh) 2017-02-15
JP5868400B2 (ja) 2016-02-24
EP2593293A4 (fr) 2017-08-16
US20130125313A1 (en) 2013-05-23
CA2804637C (fr) 2016-06-21
CA2804637A1 (fr) 2012-01-19
EP2593293A1 (fr) 2013-05-22

Similar Documents

Publication Publication Date Title
CA2804637C (fr) Systeme et procede pour former des materiaux de siege a densite variable
US20240174150A1 (en) Foam seat element, and process and mold for producing same
CN104511997B (zh) 成形体的制造方法与车辆用座椅部件的制造方法
JP2013537491A5 (fr)
KR101410963B1 (ko) 차량 시트 쿠션
US4670925A (en) Process for the production of a cushion for a seat or the back for a motor vehicle or the like comprising two layers of foamed material with different properties and cushion prepared by the process
US20020001694A1 (en) Foam molded part, method and device for producing a foam molded part for an upholstery element
EP1893395B1 (fr) Moule et son procede de fabrication
JP2006149466A (ja) シート用パッドおよびその製造方法
JP2002300936A (ja) 車両用シートパッドおよびその製造方法
EP3673768A1 (fr) Matériau de noyau de siège de véhicule et coussin de siège
JP5561101B2 (ja) ポリウレタンフォーム成形品の製造方法
JPH0976797A (ja) 自動車用座席クッション
JP3501219B2 (ja) クッション材の製造方法
JPH09168678A (ja) 自動車座席用クッション体およびその製造方法
JPS63178009A (ja) 自動車用内装部品
JP2018144761A (ja) 乗物用シート、及びその製造方法
JP2022002628A (ja) クッション体の製造方法
JP2013169927A (ja) アームレスト
JP2005087339A (ja) シート用パッドおよびその製造方法
JPS63207621A (ja) 座席用クツシヨンパツドの製造方法および座席用クツシヨンパツド用可撓性合成樹脂発泡体
JPH03128213A (ja) 部分的に硬度の異なる発泡成形体の製造方法

Legal Events

Date Code Title Description
WWE Wipo information: entry into national phase

Ref document number: 201180034315.2

Country of ref document: CN

121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 11807439

Country of ref document: EP

Kind code of ref document: A1

ENP Entry into the national phase

Ref document number: 2804637

Country of ref document: CA

WWE Wipo information: entry into national phase

Ref document number: 2011807439

Country of ref document: EP

ENP Entry into the national phase

Ref document number: 2013519789

Country of ref document: JP

Kind code of ref document: A

NENP Non-entry into the national phase

Ref country code: DE

WWE Wipo information: entry into national phase

Ref document number: 13806664

Country of ref document: US

ENP Entry into the national phase

Ref document number: 20137003567

Country of ref document: KR

Kind code of ref document: A