WO2014091500A1 - Composite en polyuréthanne pour base siège automobile - Google Patents

Composite en polyuréthanne pour base siège automobile Download PDF

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Publication number
WO2014091500A1
WO2014091500A1 PCT/IN2013/000766 IN2013000766W WO2014091500A1 WO 2014091500 A1 WO2014091500 A1 WO 2014091500A1 IN 2013000766 W IN2013000766 W IN 2013000766W WO 2014091500 A1 WO2014091500 A1 WO 2014091500A1
Authority
WO
WIPO (PCT)
Prior art keywords
seat base
automobile
mould
polyurethane
chassis
Prior art date
Application number
PCT/IN2013/000766
Other languages
English (en)
Inventor
Vikas Pramod TYAGI
Original Assignee
Varroc Polymers Pvt. 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 Varroc Polymers Pvt. Ltd. filed Critical Varroc Polymers Pvt. Ltd.
Publication of WO2014091500A1 publication Critical patent/WO2014091500A1/fr

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L75/00—Compositions of polyureas or polyurethanes; Compositions of derivatives of such polymers
    • C08L75/04—Polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/047—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2272/00—Resin or rubber layer comprising scrap, waste or recycling material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
    • B32B2307/7145—Rot proof, resistant to bacteria, mildew, mould, fungi
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings

Definitions

  • This invention relates to Automotive Seat Base made from Polyurethane (PU) composite Board.
  • PU Polyurethane
  • Salient steps involved in production of this part from a plywood include: cutting logs of wood, cooking for 12 hrs at a pre-set Temperature of 60-80 degrees to remove starch and to kill microscopic organisms, peeling the cooked log to the required thickness on the peeling machine, reeling the veneer, taking it to the clipper machine, cutting the veneer into the required dimensions, drying to a uniform temperature to reduce the moisture content to destroy microorganisms that may have survived the cooking process, adding resin to ensures uniform bonding, layering and gluing wide cross core and long panel veneer to give greater strength and dimensional stability, pre-pressing the same to give a warp-free product with uniform spread of chemical within the layers, putting each board separately into automatic hot press for polymerization at a pre set temperature to ensure uniform density at all points in the plywood, cooling the board for 24 hours after hot pressing, trimming the boards horizontally and vertically, sanding the surface in an automatic wide-belt sanding machine to give a smooth surface to the plywood which helps in a good surface finish required
  • Boards made from recycled plastics came up as a lesser costly alternative and are in use in the automobile industry since a long time; which, for the purpose of this specification shall be designated as "a board of recycled plastics combined with paper pulp".
  • waste plastic raw material itself is lesser costly than wood, its process of production is very closely similar to plywood production process, and reduction in cost is limited.
  • Steps in production of these types of products includes steps of: manual segregation of wastage of paper and polythene packaging material, shredding the segregated material by shredding machine into very small pieces, mixing shredded paper and polythene together in a required ratio and pulping the same in a tank, adding resin to the pulp to get bonding, making a seat from this material by a milling machine, drying the milled seat by heating to reduce moisture content, . laminating the board by thin polythene film, pressing the board to take a permanent shape, curing the boards for 24 hrs, cutting the board in required dimension into the seat base design shape by CNC (Computer Numeric Control) Machine, drilling the board, assembling with e BOPs and fitting the sameon chassis.
  • CNC Computer Numeric Control
  • Two wheelers generally have seat bases made from poly propylene, however, they are not techno-economically viable for three wheeler automobiles. Hence, need for further improvement continued to persist for a very long time despite use of recycled plastics and no further improvement is seen in the automobile sector so far.
  • This invention comprises a Seat Base of an automobile comprising a flat sheet of rigid material for supporting a cushion seat for a person driving the automobile and a means for connecting the flat sheet to the chassis/body of the said automobile; wherein the Seat Base and the means for connecting the same to the chassis/body of the automobile comprises a single piece composite.
  • the single piece composite of the Seat base is made by casting a polymer in to a mould and incorporating the means of connecting in that cast at the time of casting.
  • the polymer is polyurethane. However, any other polymer giving similar result may be used.
  • the means for connecting comprises the Seat base to the chassis/body of the automobile comprises a Plate Assembly which comprising a metallic plate that is embedded at one surface in matrix of the composite of the Seat Base and the other surface is connected to the chassis/body of the automobile.
  • the cushion of the Seat Base may be made from a polyurethane foam. In place of polyurethane, any other Flexible and preferably spongy material may be used.
  • the Seat Base of this invention may be fitted to, one or more, without limitation, a two wheeler, three wheeler, four wheeler or a multi-wheeler.
  • This invention also comprises a process of making a Seat Base of an automobile comprising a flat sheet of rigid material for supporting a cushion seat for a person driving the automobile and a means for connecting the flat sheet to the chassis/body of the said automobile; wherein the Seat Base and the means for connecting the same to the chassis/body of the automobile comprises a single piece composite; the process comprising the steps of: (a) making a mould of an automobile Seat Base, (b) spraying a release agent inside the mould, (c) placing Plate Assembly & reinforcement material in the mould, (d) pouring chemicals required to make a polymer that makes matrix of the composite into the mould by means of a machine, (e) closing the mould within a period of time after pouring, (f) de-moulding the cast after a period of time, curing the same, and trimming out the extra material.
  • the polymer is polyurethane
  • the chemicals required for making the polymer are Polyol and Isocyanate
  • the reinforcement material is glass fiber
  • the machine used for pouring chemicals into the mould is a high pressure polyurethane machine
  • the period of time within which mould is closed is within 5 seconds
  • the period of time after which de-moulding is done is 5-10 minutes.
  • polyurethane as polymer
  • the invention is not limited to the same and any other polymer capable of discharging same function can be used in its place wherein the chemicals, the machine and conditions for operating the machine and the process shall differ accordingly.
  • glass fiber is the reinforcement material used, any other suitable reinforcement material can be used in its place.
  • Figure 1.1 General features/structure/design/ ' parts of a Seat Assembly
  • Seat Base (3) which may be a plywood, or a board of recycled plastics combined with paper pulp, or it may also be a Polyurethane board of this invention.
  • No. 6 and No. 8 are BOPs (Bought Out Parts) that are fitted with Seat base by nails in case the Seat Base is made from plywood or a board of recycled plastics combined with paper pulp , whereas in this invention they are embedded in the matrix without the need of any nails, Polyurethane Foam (4) and PVC Leather Cloth (Rexene) (1).
  • Figure 1.2 PVC beading for seat assembly
  • Figure 2 Seat Assembly Layout (2) - Thread for Stitching. (7) - Nails used for Plate assembly ' fitment. (40) - Rexene stitching line. (41) - The- Rexene lining that is stitched taut and stapled to get an effect that there shall be a slight initial compression of the filler material - such as polyurethane foam.
  • Figure 3 (3.1) - Seat Base. Made of Ply Board.
  • Figure 4 (3.2) - Seat Base. Made of a board of recycled plastics combined with paper pulp (11-15) - Plate Assembly.
  • FIG. 5 (3.3) - Seat Base. Made of PU Composite Board. Note that this Seat Base does not comprise nails;
  • FIG. 1.1 General features/structure/design/parts of a Seat Assembly is represented by Figure 1.1 (Section A-A) that comprise a Seat Base (3) which is a flat structure fitted on chassis by means of Bought Out Parts (BOPs) that serve to attach the seat base to the chassis.
  • BOPs may comprise, without limitation, a plate assembly and nails / screws.
  • the seat assembly supports and provides anchorage to cushion on which the driver sits.
  • the cushion may, usually be composed of a material that provides a soft and comfortable surface on which a driver can sit while driving.
  • a cushion is filled with a filler that is flexible and preferably a spongy material, which may be, without limitations, cotton .wool or coir or a polyurethane foam covered by a cloth made from various material, including, without limitations, a cotton cloth or a Rexene.
  • the covering cloth is fitted on the Seat Base as well as to the filler material by means to achieve the fitment to the Seat Base, Such a means may be nails, Staple Pin or an adhesive.
  • the Seat Base was being made in plywood for a long period of time in the past. This has been replaced since a few years by a board made by recycling plastic and paper, also called as a board of recycled plastics combined with paper pulp. In both cases, the board was required to be cut in required size, drilled and then fitment of the same on the chassis was achieved through BOPs that comprised a "plate assembly"(6 in Figure 1) and nails/screws (6 in Figure 1.1). .
  • This invention embodies a "Base Plate'Vwhich is also termed as “Seat Base” and used interchangeably throughout this specification, which is connected to the chassis/body of the automobile and supports the cushion on which the person driving he automobile sits while driving, which has been made as one single piece cast as a composite of polyurethane and BOPs by a moulding process in which the BOP parts are embedded as parts of a single piece within the Base Plate.
  • Seat Base made from polyurethane
  • the seat base within the scope of this invention can be made using any other polymer that does not warp in course of time and gives rigidity enough for making a Seat Base.
  • ould used in this specification means "a shaped cavity used to give a definite form to fluid or plastic material" as given in thefreedictionary on the link http ://www. thefreedictionarv. com/mould (as accessed on 7th Dec 2012). Another meaning of this word in biology means fungi. However, the biological meaning is not applicable here.
  • the word “Mould” is British word, the American equivalent of which is “mold” which has both above meanings and may be replaced/used interchangeably here to mean "a shaped cavity used to give a definite form to fluid or plastic material”.
  • Polyurethane is used for several purposes and the application depends on its properties and the properties differ with Polyurethane of different technical specifications.
  • Polyurethane is formed by reacting isocyanate which contributes to reactive isocyanate groups, with polyols which contribute to the -OH (hydroxyl groups).
  • proportions in which they are used to make polyurethane shall determine relative proportions of these two groups in the resulting polyurethane, which control the physical properties of the polyurethane.
  • the polyurethane is made by reacting isocyanate with a polyol.
  • the reactive hydroxyl groups on the polyol are one of the important factors that determine the properties of the resulting polyurethane.
  • the resulting polyurethane has very low rigidity (flexible), and is suitable to make flexible foam for applications such as cushions above seat base and when the same is high i.e. within a range of 200 to 550mgKOH/g the resulting polyurethane is rigid and is suitable to be used to replace wooden boards.
  • the polyol and isocyanate used for making polyurethane composite and polyurethane foam had following specifications:
  • the instant invention has achieved further cost reduction and - improvement in quality -.
  • the product of this invention is useful - to the two wheelers, three wheelers, four wheelers and other automotive seat Bases.
  • This invention provides a further cost effective Automotive Seat Base wherein the raw material used is also lesser in cost and involves less steps in manufacture and fitment.
  • Seat Base of this invention may be made from any polymer that provides easy casting and mechanical strength enough for the purpose of making a Seat Base.
  • the Automobile Seat Base is made from polyurethane.
  • the seat base of this invention is strong, it does not warp in course of time and does not deteriorate in high moisture or by contact with water.
  • the invention comprises a process that comprise steps of: (a) making a mould of an automobile seat base, (b) spraying a release agent inside the mould, (c) placing Plate Assembly & reinforcement material in the mould manually, (d) pouring chemicals required to make polyurethane i.e. Polyol and Isocyanate into the mould by means of a machine, (e) closing the mould within few seconds after pouring, preferably within 5 seconds, (d) de-moulding the cast after 5-10 minutes, (e) curing the same, and (f) trimming out the extra material.
  • the said reinforcement material used is usually glass fiber. However, any other equivalent alternative may be used.
  • the machine used for pouring chemicals may be a high pressure polyurethane machine.
  • the invention gives following advantages: (a) Achievement of any kind of design /profile with single step (no need to cut the board, drill etc), (b) easy to Process (made in single process with all BOP - no additional Assembly required), (c) it can be produced on regular high pressure PU (Polyurethane) machine, (d) water resistance (water proof board), (e) lower cost than Ply Board seat base, (f) absence of warping of the edge, (g) high tensile strength, (h) termite, borer, bacteria resistance, (i) low density (light weight), (j) easy to drill , to cut, (k) long life, (1) resistance to chemicals, oil, gasoline, (m) time saving process (elimination post assembly process), (n) better in aesthetics, (O) its 5mm thickness is more stronger then 8mm thickness of board made by packaging waste material, (p) a seat base made form a polymer, particularly form PU, gives weight reduction advantage to the vehicle/automobile which helps in fuel economy and also it reduces the C

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

Cette invention concerne une base siège automobile et son procédé de fabrication. La base siège comprend une feuille plate en un matériau rigide destinée à supporter le siège de type à coussins du conducteur de l'automobile et un moyen de fixation de ladite feuille plate au châssis et/ou à la carrosserie de ladite automobile. La base siège et son moyen de fixation au châssis et/ou à la carrosserie de l'automobile comprend un composite monolithique obtenu par coulée d'un polymère dans un moule et incorporation dudit moyen de fixation dans la pièce coulée lors du coulage. Dans un mode de réalisation représentatif, le polymère est un polyuréthanne. Le moyen de fixation comprend un ensemble plaque constitué d'une plaque métallique qui est noyée dans une surface de la matrice du composite de la base siège, l'autre surface étant fixée au châssis et/ou à la carrosserie du véhicule. La base siège selon l'invention peut s'adapter, sans limitation, à un ou plusieurs véhicules deux-roues, trois-roues, quatre-roues ou multi-roues.
PCT/IN2013/000766 2012-12-13 2013-12-12 Composite en polyuréthanne pour base siège automobile WO2014091500A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN3511MU2012 2012-12-13
IN3511/MUM/2012 2012-12-13

Publications (1)

Publication Number Publication Date
WO2014091500A1 true WO2014091500A1 (fr) 2014-06-19

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PCT/IN2013/000766 WO2014091500A1 (fr) 2012-12-13 2013-12-12 Composite en polyuréthanne pour base siège automobile

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016016905A3 (fr) * 2014-07-31 2016-06-23 Varroc Polymers Pvt. Ltd. Polyuréthane pour rondelle isolante/amortisseur de siège automobile monté(e) sur une base de siège de motocyclette

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3632533A (en) * 1967-10-31 1972-01-04 Tenneco Chem Heat-sealable polyurethane foam
US4313776A (en) * 1978-12-14 1982-02-02 Tachikawa Spring Co., Ltd. Method of producing seat cushion member
US4541885A (en) * 1983-06-10 1985-09-17 General Motors Corporation Method of manufacturing a vehicle seat cover
WO1991013112A1 (fr) * 1990-02-20 1991-09-05 Frisch Kurt C Composites alveolaires renforces comprenant une resine d'ester vinylique a hydroxy
US5762842A (en) * 1996-08-30 1998-06-09 Burchi; Charles R. Process for seat production
WO2005090431A1 (fr) * 2004-03-11 2005-09-29 Dow Global Technologies, Inc. Mousses de polyurethane rigides, adhesives, a forte reactivite
EP1679327A1 (fr) * 2003-10-28 2006-07-12 Mitsui Chemicals Polyurethanes, Inc. Mousse de polyurethanne flexible et utilisation de celle-ci
EP1813632A1 (fr) * 2004-11-18 2007-08-01 Asahi Glass Company, Limited Procédé servant à produire une mousse de polyuréthane flexible

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3632533A (en) * 1967-10-31 1972-01-04 Tenneco Chem Heat-sealable polyurethane foam
US4313776A (en) * 1978-12-14 1982-02-02 Tachikawa Spring Co., Ltd. Method of producing seat cushion member
US4541885A (en) * 1983-06-10 1985-09-17 General Motors Corporation Method of manufacturing a vehicle seat cover
WO1991013112A1 (fr) * 1990-02-20 1991-09-05 Frisch Kurt C Composites alveolaires renforces comprenant une resine d'ester vinylique a hydroxy
US5762842A (en) * 1996-08-30 1998-06-09 Burchi; Charles R. Process for seat production
EP1679327A1 (fr) * 2003-10-28 2006-07-12 Mitsui Chemicals Polyurethanes, Inc. Mousse de polyurethanne flexible et utilisation de celle-ci
WO2005090431A1 (fr) * 2004-03-11 2005-09-29 Dow Global Technologies, Inc. Mousses de polyurethane rigides, adhesives, a forte reactivite
EP1813632A1 (fr) * 2004-11-18 2007-08-01 Asahi Glass Company, Limited Procédé servant à produire une mousse de polyuréthane flexible

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
MIHAIL LONESCU: "Chemistry & Technology of polyols for polyurethanes", 2005, pages 101, 317 *

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016016905A3 (fr) * 2014-07-31 2016-06-23 Varroc Polymers Pvt. Ltd. Polyuréthane pour rondelle isolante/amortisseur de siège automobile monté(e) sur une base de siège de motocyclette

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