GB2144071A - Method and apparatus for producing upholstery bodies from moulded foam - Google Patents
Method and apparatus for producing upholstery bodies from moulded foam Download PDFInfo
- Publication number
- GB2144071A GB2144071A GB08416997A GB8416997A GB2144071A GB 2144071 A GB2144071 A GB 2144071A GB 08416997 A GB08416997 A GB 08416997A GB 8416997 A GB8416997 A GB 8416997A GB 2144071 A GB2144071 A GB 2144071A
- Authority
- GB
- United Kingdom
- Prior art keywords
- mould
- moulded
- mixtures
- members
- separating
- Prior art date
- Legal status (The legal status 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 status listed.)
- Granted
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
- A47C7/18—Seat parts having foamed material included in cushioning part
-
- 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
- B29C44/0461—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 having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other
- B29C44/0469—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 having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other provided with physical separators between the different materials, e.g. separating layers, mould walls
Landscapes
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
In a method of producing moulded upholstery bodies having regions of different hardness, a mould (8) is provided with one or more separating members (6) which divide the mould into discrete portions. Differently-constituted foam-forming mixtures are introduced into discrete portions of the mould. The separating members (6) prevent the mixtures from flowing into one another at least during the first phase of the foaming. <IMAGE>
Description
SPECIFICATION
Method and apparatus for producing upholstery bodies from moulded foam
This invention relates to a method of producing upholstery bodies from moulded foam, (the upholstery bodies being particularly useful for vehicle seats), in which, to provide regions of different hardness, two or more mixtures of different composition are foamed side-by-side in a mould. the present invention also relates to apparatus for carrying out the said method.
In upholstery bodies,especially in the case of seat cushions and squabs, it is frequently desired to have different degrees of hardness in the central portion and in the edge or bead portions. for example, the central portion may be of lower hardness than the edge or bead portions.
Methods of moulding are known which make it possible to produce upholstery bodies from, e.g., polyurethane or latex foam, which have the aforementioned areas of different hardness.
This has hitherto been achieved by foaming-in reinforcing elements which are, for example, cut from compound foam or produced from appropriately-shaped hardffoam parts. Also, appropriately shaped metal inserts are known.
These known production methods incur considerable production expenditure and the results which can be achieved thereby are frequently unsatisfactory.
German Offenlegungsschrift No 31 o2 140 describes a method for producing upholstery bodies having regions of different hardness.
This is done by dispensing a plurality of foamforming mixtures, each mixture having a different composition, into individual zones of a mould cavity, the mixtures being so introduced that they flow towards one another and into one another in the mould and form overlapping mouldings in the form of tablike extensions and beads.
However, this method hs the disadvantage that the demarcation lines between the various portions of different hardness arise largely fortuitously, so that no exactly definable and reproducible separation can be achieved. this in turn has an unfavourable effect on the required properties of the moulded body.
The object of the invention is to provide a foamed upholstery body having regions of different hardness which can be accurately and reproducible made without undue expenditure and additional process features.
This is achieved by introducing the different foam-fforming mixtures into reception zones of a mould which are separated from one another so as to prevent the mixtures from flowing into one another, this separation of the mixtures being maintained at least during the first phase of the foaming.
Accordingly, the present invention provides a method of producing upholstery bodies from moulded foam, in which, to provide regions of different hardness, two or more mixtures of different composition are foamed side-by-side in a mould, the different mixtures being introduced into portions of the mould which are separated from one another so as to prevent the mixtures from flowing into one another, the separation of the mixtures being maintained during at least the first phase of the foaming.
The present invention also provides apparatus for carrying out the method described in the immediately-preceding paragraph, said apparatus comprising a casting mould of metal or a plastics material, said mould being provided with one or more separating members which extend upwardly from the bottom of the mould in accordance with the desired plane of separation between foamed regions of different hardness.
These separating members, which can readily be installed without ,undue expenditure, in any desired configuration and position, prevent the mixtures from flowing into one another prior to and during the first phase of the foaming, which leads to the formation of a surprisingly accurate separation between the zones of different hardness. The position and the course of the demarcation lines can be varied by changing the height of the separating members and/or by varying their configuration. Preferably, each separating member is disposed substantially vertically in the mould.
The height of the separating members is suitably in the range 10% to 70% of the depth of the mould, preferably 30% to 50% of the mould depth.
In one preferred embodiment, additional vertical members are provided in the mould at points corresponding to the transitions between the central portion and the bead portions of the moulded body. The height of these additional vertical members is small compared to that of the separating members.
In a second preferred embodiment, the mould has a substantially flat centre portion and two lateral sunken bead portions with arcuate bottom surfaces. The separating members are attached to those parts of the arcuate bottom surfaces which rise towards the central portion.
It will be seen, therefore, that adjacent regions of different hardness in the resulting moulded body will define slots corresponding to the separating members.
The moulded body will also have seam slots, corresponding to the additional vertical members, which separate the central portion from the bead portions.
The slots corresponding to the separating members are of greater depth than those corresponding to the additional vertical mem bers.
By suitable pigmentation of the mixtures of different composition, the exact separation of areas of different hardness can readily be made visible in the moulded product.
The slots in the moulded product which correspond to the separating members in the mould do not affect the upholstering of the moulded body in any way.
One embodiment of the invention will be illustrated, merely by way of example, in the following description and with reference to the accompanying drawings.
In the drawings:
Figure 1 is a schematic sectional view of apparatus in accordance with the present invention;
Figure 2 is a perspective view of a moulded body made in the apparatus of Figure 1, and
Figure 3 is a section on line a-a of figure 2.
Referring now to figure 1, a casting mould 8 comprises a central portion 1 and bead portions 2 which, in comparison with the central portion, are deeper and have an arcuate bottom surface. the central portion 1 and bead portions 2 are filled with foam-forming mixtures of different composition so that the resulting moulded body will have regions of different hardness.
At the transitional points between the central portion 1 and the bead portions 2 are the additional vertical members 5. Although vertical members 5 produce, in the moulded body, a certain demarcation between regions of different hardness, the definition of said regions of different hardness is achieved by means of the separating members 6 which extend substantially vertically 'upwards from those parts of the arcuate surfaces of the bead portions 2 which rise towards the central portion 1. the separating members 6 have a height in the range 30% to 50% of the depth of the mould.
In making an upholstery body by means of the mould shown in Figure 1, differentlyconstituted foam-forming mixtures are placed into the bead portions 2 and the central portion 1. The separating members 6 prevent the interflow of the mixtures prior to, as well as in the first phase of, the foaming, which leads to a surprisingly exact definition of the zones of different hardness. The relatively small height (i.e. 30% to 50% of the mould depth) of the separating members 6 is, surprisingly, sufficient to ensure this exact separation through the entire moulded body.
Referring now to figure 2, a seat-pad 3 (e.g. for motor vehicles) has a comparatively soft seat portion 10 and, in comparison thereto, harder bead portions 9. These harder bead portions provide greatly improved support for the user especially when the vehicle is cornering.
Slots 7 are produced by means of the separating members 6. The presence of these slots 7 is not in any way deleterious after the
moulded body has been covered and the slots
moreover do not impair the properties of the
moulded body.
The seam slots 12 which result from the additional vertical members 5 have only a comparatively slight depth.
The sectional view shown in Figure 3 illustrates the course of the demarcation lines
resulting from the use of the separating mem
bers, between the zones of different hardness.
These demarcation lines 11, which separate the softer central portion 10 from the harder
bead portions 9, are partly predetermined by the corresponding separating members, and partly exactly developed during moulding along the remaining moulded portion. Thus, by means of the method and apparatus according to the present invention, the structure and properties of the moulded body can be predetermined very accurately.
Claims (12)
1. A method of producing upholstery bodies from moulded foam, in which, to provide regions of different hardness, two or more mixtures of different composition are foamed side-by-side in a mould, the different mixtures being introduced into portions of the mould which are separated from one another so as to prevent the mixtures from flowing into one another, the separation of the mixtures being maintained during at least the first phase of the foaming.
2. Apparatus for carrying out the method according to Claim 1, said apparatus comprising a casting mould of metal or a plastics material, said mould being provided with one or more separating members which extend upwardly from the bottom of the mould in accordance with the desired plane of separation between foamed regions of different hardness.
3. Apparatus according to Claim 2, in which each separating member is disposed substantially vertically in the mould.
4. Apparatus according to Claim 2 or 3, in which the height of each separating member is in the range 10% to 70% of the depth of the mould.
5. Apparatus according to Claim 4, in which the height of each separating member is in the range 30% to 50% of the depth of the mould.
6. Apparatus according to any one of
Claims 2 to 5, in which the mould comprises a substantially flat centre portion and two sunken lateral bead portions having arcuate bottom surfaces, the separating members being attached to those parts of the arcuate bottom surfaces which rise towards the central portion.
7. Apparatus according to Claim 6, in which additional vertical members are provided at the transitions between the central portion and the bead portions, the height of said additional vertical members being small in comparison to that of the separating members.
8. A moulded foamed body made in the apparatus according to any one of Claims 2 to 7, in which adjacent regions of different hardness define slots corresponding to the separating members.
9. A moulded foamed body made in the apparatus according to Claim 7, in which seam slots, corresponding to the additional vertical members, separate the central portion from the lateral bead portions of the moulded body,
10. A moulded foamed body according to
Claim 8 or 9, in which the slots corresponding to the separating members are of greater depth than those corresponding to the additional vertical members.
11. A moulded foamed body made by the method of Claim 1.
12. Apparatus for producing a moulded foamed body, substantially as hereinbefore described, with reference to and as illustrated in Figure 1 of the accompanying drawings.
1 3. A moulded foamed body, substantially as hereinbefore described, with reference to and as illustrated in Figures 2 and 3 of the accompanying drawings.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE19833327724 DE3327724A1 (en) | 1983-08-01 | 1983-08-01 | METHOD AND DEVICE FOR PRODUCING UPHOLSTERY BODIES FROM MOLDED FOAM |
Publications (3)
Publication Number | Publication Date |
---|---|
GB8416997D0 GB8416997D0 (en) | 1984-08-08 |
GB2144071A true GB2144071A (en) | 1985-02-27 |
GB2144071B GB2144071B (en) | 1986-06-04 |
Family
ID=6205471
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB08416997A Expired GB2144071B (en) | 1983-08-01 | 1984-07-04 | Method and apparatus for producing upholstery bodies from moulded foam |
Country Status (3)
Country | Link |
---|---|
DE (1) | DE3327724A1 (en) |
GB (1) | GB2144071B (en) |
ZA (1) | ZA845456B (en) |
Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2157559A (en) * | 1984-04-16 | 1985-10-30 | Nhk Spring Co Ltd | Seat pads |
GB2182604A (en) * | 1985-11-05 | 1987-05-20 | Bridgestone Corp | Method for making moulded foamed articles having a laminar structure |
EP0227489A2 (en) * | 1985-12-25 | 1987-07-01 | Honda Giken Kogyo Kabushiki Kaisha | Production of laminated resin foam |
GB2185392A (en) * | 1986-01-20 | 1987-07-22 | Kawashima Textile Mills | Apparatus for displaying a sample of upholstery material |
GB2197659A (en) * | 1986-11-20 | 1988-05-25 | Bp Chem Int Ltd | Process for preparing polyurethane foams having zones of differing hardness |
GB2199739A (en) * | 1986-12-01 | 1988-07-20 | Bridgestone Corp | Cushion |
US5000515A (en) * | 1989-02-14 | 1991-03-19 | Hoover Universal, Inc. | Variable density foam vehicle seat |
EP1449463A1 (en) * | 2001-11-26 | 2004-08-25 | Bridgestone Corporation | Seat pad for vehicle |
US20130214583A1 (en) * | 2012-02-22 | 2013-08-22 | Toyobo Co., Ltd. | Cushion pad for car seat |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB612029A (en) * | 1946-05-15 | 1948-11-08 | Christian Kunzle | Improvements in and relating to the manufacture of chocolate or other sweetmeat slabs, bars or the like |
GB701841A (en) * | 1951-03-13 | 1954-01-06 | Frederick Robert Taylor | Tanks for moulding jellies or like confections |
GB1160558A (en) * | 1965-09-22 | 1969-08-06 | Alan Bertie | Improvements in or relating to the Casting of Concrete Crazy Paving Slabs |
DE2052907A1 (en) * | 1970-10-28 | 1972-05-04 | Tech Akustik Gmbh & Co | Moulding foamed plastics seats - esp for automobiles having differing local properties |
Family Cites Families (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE3102140A1 (en) * | 1981-01-23 | 1982-08-19 | Bayer Ag, 5090 Leverkusen | MOLDED PART, ESPECIALLY UPHOLSTERY FOR VEHICLE SEATS, MADE OF POLYURETHANE FOAM WITH ZONES OF DIFFERENT IMPRESSION HARDNESS, AND METHOD FOR THE PRODUCTION THEREOF |
-
1983
- 1983-08-01 DE DE19833327724 patent/DE3327724A1/en active Granted
-
1984
- 1984-07-04 GB GB08416997A patent/GB2144071B/en not_active Expired
- 1984-07-16 ZA ZA845456A patent/ZA845456B/en unknown
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB612029A (en) * | 1946-05-15 | 1948-11-08 | Christian Kunzle | Improvements in and relating to the manufacture of chocolate or other sweetmeat slabs, bars or the like |
GB701841A (en) * | 1951-03-13 | 1954-01-06 | Frederick Robert Taylor | Tanks for moulding jellies or like confections |
GB1160558A (en) * | 1965-09-22 | 1969-08-06 | Alan Bertie | Improvements in or relating to the Casting of Concrete Crazy Paving Slabs |
DE2052907A1 (en) * | 1970-10-28 | 1972-05-04 | Tech Akustik Gmbh & Co | Moulding foamed plastics seats - esp for automobiles having differing local properties |
Cited By (18)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2157559A (en) * | 1984-04-16 | 1985-10-30 | Nhk Spring Co Ltd | Seat pads |
US4975229A (en) * | 1985-04-16 | 1990-12-04 | Honda Giken Kogyo Kabushiki Kaisha | Process for producing laminated resin foam |
GB2182604B (en) * | 1985-11-05 | 1990-04-04 | Bridgestone Corp | Method for making foamed articles having a laminated structure |
GB2182604A (en) * | 1985-11-05 | 1987-05-20 | Bridgestone Corp | Method for making moulded foamed articles having a laminar structure |
EP0227489A2 (en) * | 1985-12-25 | 1987-07-01 | Honda Giken Kogyo Kabushiki Kaisha | Production of laminated resin foam |
EP0227489A3 (en) * | 1985-12-25 | 1988-09-14 | Honda Giken Kogyo Kabushiki Kaisha | Production of laminated resin foam |
GB2185392A (en) * | 1986-01-20 | 1987-07-22 | Kawashima Textile Mills | Apparatus for displaying a sample of upholstery material |
GB2197659A (en) * | 1986-11-20 | 1988-05-25 | Bp Chem Int Ltd | Process for preparing polyurethane foams having zones of differing hardness |
GB2197659B (en) * | 1986-11-20 | 1990-01-10 | Bp Chem Int Ltd | Process for preparing polyurethane foams having zones of differing hardness |
GB2199739B (en) * | 1986-12-01 | 1990-01-24 | Bridgestone Corp | Cushioning stuff and manufacturing method of the same |
GB2199739A (en) * | 1986-12-01 | 1988-07-20 | Bridgestone Corp | Cushion |
US5000515A (en) * | 1989-02-14 | 1991-03-19 | Hoover Universal, Inc. | Variable density foam vehicle seat |
EP1449463A1 (en) * | 2001-11-26 | 2004-08-25 | Bridgestone Corporation | Seat pad for vehicle |
EP1449463A4 (en) * | 2001-11-26 | 2006-01-04 | Bridgestone Corp | Seat pad for vehicle |
US20130214583A1 (en) * | 2012-02-22 | 2013-08-22 | Toyobo Co., Ltd. | Cushion pad for car seat |
CN103287299A (en) * | 2012-02-22 | 2013-09-11 | 丰田纺织株式会社 | Cushion pad for car seat |
US9266455B2 (en) * | 2012-02-22 | 2016-02-23 | Toyota Boshoku Kabushiki Kaisha | Cushion pad for car seat |
CN103287299B (en) * | 2012-02-22 | 2017-11-07 | 丰田纺织株式会社 | Cushion pad for seat |
Also Published As
Publication number | Publication date |
---|---|
GB8416997D0 (en) | 1984-08-08 |
DE3327724A1 (en) | 1985-02-14 |
DE3327724C2 (en) | 1987-05-27 |
ZA845456B (en) | 1986-02-26 |
GB2144071B (en) | 1986-06-04 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
EP1871197B1 (en) | Foam seat element, mold for the production thereof and method to manufacture the mold | |
US5000515A (en) | Variable density foam vehicle seat | |
US3874731A (en) | Injection molded seating | |
US6755475B1 (en) | Multiple indentation load deflection foam molding | |
US4265484A (en) | Reinforced foamed body support member | |
GB2144071A (en) | Method and apparatus for producing upholstery bodies from moulded foam | |
EP1083817B1 (en) | Toilet seat and lid assembly | |
US4762654A (en) | Method for making foamed articles having a laminated structure | |
GB2157559A (en) | Seat pads | |
EP3344429A1 (en) | Vented mold | |
GB2197659A (en) | Process for preparing polyurethane foams having zones of differing hardness | |
EP1893395B1 (en) | Mold and method for manufacture thereof | |
US4975229A (en) | Process for producing laminated resin foam | |
EP0431981A2 (en) | Making polyurethane seat paddings | |
KR101450027B1 (en) | System and method of forming variable density seating materials | |
JP2002300936A (en) | Seat pad for vehicle and manufacturing method therefor | |
JPH0322284B2 (en) | ||
JPS63222813A (en) | Manufacture of cushion, particularly, seat cushion for automobile | |
GB2306910A (en) | Moulding articles having regions of differing hardness | |
JPH02276606A (en) | Manufacture and mold of different hardness cushioning body | |
JPH0531974Y2 (en) | ||
JPH0564819A (en) | Mold of composite cushioning body for seat or the like | |
GB2213094A (en) | Method for making foamed articles having a laminated structure | |
JPH04150890A (en) | Cushion for automobile and its production | |
JPS6274310A (en) | Seat cushion and its production |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
732E | Amendments to the register in respect of changes of name or changes affecting rights (sect. 32/1977) | ||
PCNP | Patent ceased through non-payment of renewal fee |
Effective date: 19970704 |