WO2007115396A1 - composant de meuble à revêtement mince et procédé et appareil pour la production de celui-ci - Google Patents

composant de meuble à revêtement mince et procédé et appareil pour la production de celui-ci Download PDF

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Publication number
WO2007115396A1
WO2007115396A1 PCT/CA2007/000553 CA2007000553W WO2007115396A1 WO 2007115396 A1 WO2007115396 A1 WO 2007115396A1 CA 2007000553 W CA2007000553 W CA 2007000553W WO 2007115396 A1 WO2007115396 A1 WO 2007115396A1
Authority
WO
WIPO (PCT)
Prior art keywords
mould
product
polyurethane elastomer
spraying
station
Prior art date
Application number
PCT/CA2007/000553
Other languages
English (en)
Inventor
Robert W. Germann
Original Assignee
Custom Foam Systems 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 Custom Foam Systems Ltd. filed Critical Custom Foam Systems Ltd.
Publication of WO2007115396A1 publication Critical patent/WO2007115396A1/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
    • A47C7/54—Supports for the arms
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/34—Moulds or cores; Details thereof or accessories therefor movable, e.g. to or from the moulding station
    • B29C33/36—Moulds or cores; Details thereof or accessories therefor movable, e.g. to or from the moulding station continuously movable in one direction, e.g. in a closed circuit
    • 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
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0067—Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other
    • 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
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1228—Joining preformed parts by the expanding material
    • B29C44/1233—Joining preformed parts by the expanding material the preformed parts being supported during expanding
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/03—Injection moulding apparatus
    • B29C45/04—Injection moulding apparatus using movable moulds or mould halves

Definitions

  • the present invention relates to furniture components in general and to a new armrest material in particular.
  • Most office chairs are provided with armrests on which the user can rest his or her arms while conducting office-related tasks such as reading or typing.
  • the comfort or feel of the armrest plays a significant role in the comfort level of the worker while the appearance, feel and wear resistance play a significant role in the life of the armrest and the attractiveness or appeal to the potential purchaser.
  • From the standpoint of the manufacturer it is important that the office chair be comfortable and appealing to the customer and it is also important that the cost of the chair components be as inexpensive as possible while providing all of the desirable qualities that will appeal to the customer so that the manufacturer can provide a product that will fulfill the customer's needs and desires while providing a suitable level of profit.
  • the office chair With the recent emphasis on ergonomic correctness in the workplace, in view of keyboarding-related physical problems such as carpal tunnel syndrome and neck and shoulder injuries, it is important that the office chair provide adequate support for the worker's body and extremities.
  • the armrest portion of an office chair it is desirable that the armrest provide a degree of compression when the arm or elbow is resting thereon, without being so soft that the worker can feel the underlying support structure.
  • the armrest should not be so hard that it is little different from a piece of wood covered with a thin fabric cover, providing little or no comfort to the user.
  • CFS Custom Foam Systems
  • TUFFSKINTM is a two component product that is used to make tractor seats. It utilizes an outer skin of an elastomer material that is first of all sprayed into a suitable mould to a thickness in the order of 1 mm (typically from about 0.9 mm to about 1.5 mm).
  • the elastomer used is a special polyurethane material co-developed by CFS and Bayer Material Science, which material increases the physical properties of standard polyurethane elastomers at thinner cross-sections than typically processed.
  • the TUFFSKINTM product also utilizes a polyurethane foam material that is blown into the mould once the skin material has been sprayed onto the surface of the mould and the mould has been closed. The foam is injected using water as the blowing agent.
  • the elastomer skin and the blown foam create a chemical bond as the materials cure within the mould.
  • the resulting part has an elastomeric outer skin which typically has a black textured surface and it has a flexible foam supporting body, shaped to the desired profile of the seat.
  • the TUFFSKINTM product exhibits an outer thin skin that has a density of about 60 pounds per cubic foot (pcf) and a core or support with a density of about 3.5 pcf.
  • the traditional product, where the outer skin forms autonomously on the foam has an even thinner skin but it has a consistent density of about 25 pcf throughout.
  • the TUFFSKINTM product exhibits better abrasion, mare and cut resistance and tear strength with much less compression.
  • the elastomer skin had to be highly consistent and thin to yield an attractive result. If the spray skin "pooled” or varied or was overall too thick, the resulting part would feel too hard or the pooling would be noticeable to the touch.
  • the consistency of the skin thickness is also a critical element in maximizing the durability of the product. Any significant transition from thick to thin creates a "hinge point" where under repeated compressions there can be premature failure of the product.
  • CFS has been able to automate the production of TUFFSKINTM products, such that the polyurethane elastomer for the skin is sprayed robotically into the moulds, whereby skin thickness can be closely controlled.
  • this product finds particular use in tractor seats, although if a thicker skin is provided the product can be shaped and moulded for other high-usage products.
  • Another CFS product that finds particular acceptance in the office furniture business is their GELFOAMTM product, again co-developed with Bayer Material Science.
  • GELFOAMTM is a variation of microcellular polyurethane which possesses the surface characteristics of self-skinning or integral skin foam, except that when squeezed or compressed by hand and released it reacts like a conventional gel material but with its own distinguishing recovery cycle and feel.
  • GELFOAMTM was also formulated to ensure that the finished moulded product has physical properties consistent with self-skinning foam. Physical properties necessary to be serviceable for armrest applications include abrasion resistance, mare resistance and elongation. This product was developed to gain market share in applications where gel products were growing, as for example in computer keyboard wrist rests, office chair armrests and stress relieving novelty items such a squeeze-balls. In accelerated field use tests GELFOAMTM products performed consistently well when compared to other self-skinning materials but did not perform as well as most PVC skin products.
  • the needs established by the furniture manufacturers have been met with the product of the present invention, namely a two-component material that is particularly suitable for use as an armrest on an office chair that provides excellent wear resistance, as well as excellent appearance and feel at a reasonable cost to the furniture manufacturer.
  • the material of the invention includes a polyurethane elastomer material that is sprayed onto the internal surface of a mould as a consistent and uniform thin layer over what will be the operating surface of an armrest. When the mould is closed a self-skinning gel-like microcellular polyurethane material such as GELFOAMTM is injected into the mould to fill the mould to a desired level.
  • the two materials will bond together as the materials cure within the mould, and when the resulting moulded product is removed from the mould it will exhibit all of the desirable traits that the furniture manufacture is seeking.
  • the outer skin has the desired, preferably textured, appearance while exhibiting excellent abrasion resistance, mare resistance and elongation, while the body of the product exhibits the desired compression resistance and recovery characteristics that appeal to the ultimate user of an armrest, the office worker.
  • the present invention also contemplates apparatus for manufacturing appropriate product, including armrests for office chairs.
  • the apparatus of this invention contemplates a 10-station carousel, with each station comprising an independent pneumatically-operated mould press.
  • a 10-station operation was considered to be optimum on the basis of the cure time of 5 minutes. With each of the operation process steps taking approximately one minute, including the robot spraying of the elastomer skin material, and there being four other operation steps involved, a 10-station operation turned out to be most effective and efficient.
  • the present invention is seen to contemplate a moulded product exhibiting a smooth and wear resistant outer surface and a compressible supporting body portion, the product comprising: a supporting frame member; the supporting body portion being formed from a gel-like microcellular polyurethane foamable material and encapsulating the frame member; and the outer surface being formed from a polyurethane elastomer material having a thickness in the range of about 0.5 mm to 0.9 mm, the polyurethane elastomer material and the gel-like foamable material being bonded together to form an integral body for the product.
  • the present invention also contemplates a method for producing a moulded product utilizing a mould including first and second mating sections that can be opened and closed relative to each other and which define a cavity profiled to the shape of such product, comprising the steps of: spraying a release agent onto an interior surface of at least the first mould section; spraying a thin layer of a polyurethane elastomer onto the release agent; removing any overspray of polyurethane elastomer from the first mould section; inserting a supporting frame member for the product into the first mould section; closing the first and second mould sections and injecting into the mould cavity defined by the mould sections a gel-like self-skinning microcellular polyurethane foamable material; permitting the foamable material to expand and fill the mould cavity and to bond to the polyurethane elastomer as the polyurethane elastomer and the foamable material cure within the mould cavity; and removing the moulded product from the mould following the curing of the polyurethane elastomer and
  • the present inventions contemplates apparatus for producing a moulded product, the apparatus comprising: a carousel defining a plurality of circumferentially spaced moulds at the outer periphery thereof, each such mould including first and second mating sections that can be opened and closed relative to each other and which define a cavity profiled to the shape of the product; a plurality of operation stations spaced apart around the carousel; means for rotating the carousel to present each mould respectively and in timed sequence to the operating stations seriatim; a first station including first spraying means for spraying a release agent onto an interior surface of at least the first mould section present at the first station; a second station including second spraying means for spraying a polyurethane elastomer onto the release agent; a third station including means for removing any overspray of the polyurethane elastomer from the first mould section; means at third station for inserting a supporting frame member into the first mould section; a fourth station including means for closing
  • Figure 1 is a cross-sectional view of a typical armrest for an office chair incorporating the material combination of the present invention
  • Figure 2 is a flow chart indicating the steps involved in the process of the present invention.
  • FIG. 3 is a schematic representation of the apparatus which is effective in carrying out the process of the present invention.
  • the present invention incorporates many, if not all, of the advantageous aspects of the TUFFSKINTM and the GELFOAMTM products already manufactured by CFS.
  • the gel-like foam material used in the single component GELFOAMTM product which material is of the self-skinning variety, is compatible with the polyurethane elastomer used as the skin material in the two- component TUFFSKINTM product.
  • the gel-like foam material is brought into contact with the polyurethane elastomer there is a bonding between the two materials as they cure, with the result being a supporting body of the gel-like foam material covered by a thin skin of the polyurethane elastomer.
  • the skin of the ensuing product exhibits all of the desirable qualities indicated above, while the supporting material exhibits the desirable qualities of the GELFOAMTM product, also as indicated above.
  • the ensuing product is an armrest for an office chair the product becomes highly desirable for the furniture manufacturer, as it provides optimum comfort, with excellent wear resistance, mare resistance, cut resistance, abrasion resistance and elongation. It has also been ascertained that it is possible to decrease the skin thickness typically associated with the TUFFSKINTM product without decreasing the desirable properties of the skin, thereby reducing manufacturing costs.
  • FIG 1 is illustrative of a typical armrest utilizing the principles of the present invention.
  • the armrest 10 is shown in transverse cress-section, whereby it includes a frame member 12 that is typically of a plastic material, although it could also be formed of aluminum, wood, or any other supporting material.
  • the frame member 12 will provide stability to the armrest after moulding and it will also serve as an anchor for the armrest when it is assembled to a suitable supporting frame of the office chair.
  • the formed armrest 10 will also exhibit the supporting material 14 which is formed to the desired shape of the armrest, and which also is moulded about the frame member 12 so as to fix the frame member in place within the armrest 10.
  • the material 14 starts as a gel-like foamable self-skinning microcellular polyurethane material such as GELFOAMTM currently available from CFS.
  • a self-skinning material is one which, as it cures, forms a thin skin on its exterior surface.
  • the exterior skin of such a material will often be acceptable as the exterior surface of a product and such material is not usually associated with other exterior materials since such exterior materials are not required for applications in which such gel-like material is used.
  • the armrest 10 of the present invention also incorporates an exterior surface or layer 16 formed from a polyurethane elastomer that is moulded along with the gel-like foam material in a mould press.
  • the polyurethane elastomer is sprayed onto the appropriate surface of the mould before the gel-like foam material is injected into the mould, such that the polyurethane elastomer and the gel-like foam material will bond together as they cure.
  • the moulded armrest will thus exhibit the properties or characteristics of a gel-like foam material with an attractive outer surface formed by the polyurethane elastomer, achieving all of the desirable characteristics of the TUFFSKINTM and GELFOAMTM products at a reasonable manufacturing cost, making for a very attractive product for the furniture manufacturer.
  • the mould surface will preferably be etched so that the exterior surface of the layer 16 will exhibit a generally textured appearance, which is appealing to most customers.
  • Figure 2 illustrates a flow chart which sets forth the method of the present invention, in association with Figure 3 which illustrates schematically the apparatus especially adapted to produce the product of the present invention.
  • the method and the apparatus comprise a plurality of steps accomplished at an equivalent plurality of operation stations, each adapted to perform a specific operation, although five of the stations are utilized for the curing of the polymeric materials forming the product.
  • the method of the invention starts with step 50, the spraying of a mould release agent 100 onto the operative surfaces of an open mould 200 at the first station 300, the mould cavity reflecting the final shape of the product to be moulded therein.
  • the mould 200 includes first and second mould sections 202 and 204.
  • the mould section 202 is fixed to a carousel 206 that rotates in a timed fashion to bring each mould seriatim to each operation station.
  • the second mould section 204 travels with the first mould section and is movable relative thereto so as to open and close the mould itself as desired.
  • Each mould section has a portion of the product profile or shape formed therein such that the mould cavity is defined by the mould sections when the mould is closed.
  • the second step 52 involves the optional spraying of a thin film of an appropriate colouring agent, such as paint 102 onto the release agent in the mould 200, also at the first station 300.
  • the third step 54 involves the robotic spraying, by way of a robot 302, of the polyurethane elastomer 104 that will form the skin 16 of the product, into the mould 200 at the second station 304. With the robotic spraying of the elastomer into the mould 200 it is possible to carefully control the thickness of the material such that the thickness of the skin 16 will be in the range of from about 0.5 mm to about 0.9 mm, much less than that of the TUFFSKINTM product.
  • the fourth step 56 involves scraping any overspray of the polyurethane elastomer from the mould along the parting line 18 of the skin 16 as shown in Figure 1.
  • This step takes place at the third station 306 and will ensure that there is a clean line where the skin 16 meets the material of the supporting body 14.
  • the fifth step 58 also takes place at the third station 306 and involves positioning the frame member 12 into the mould cavity 200.
  • the frame member will be supported by appropriate supports within the cavity so that the gel-like material can flow around the frame member and thus fix it in place within the final product.
  • the sixth step 60 takes place at the fourth station 308 where the mould sections 202, 204 are brought together to close the mould, so that the mould cavity will enclose the final form of the product to be moulded therein.
  • the gel- like self-skinning microcellular polyurethane foam material 106 is injected into the mould cavity.
  • the fifth through ninth stations 310-318 involve the curing step 62 of the polyurethane elastomer and the gel-like foam material as they bond together and form around the frame member 12 to result in the desired final product.
  • the seventh and last step 64 takes place at the tenth station 320 where the first and second mould sections 202, 204 are separated to open the mould 200 so that the final product 10 can be removed therefrom.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un produit moulé particulièrement adéquat en tant qu'accoudoir pour un fauteuil présentant une surface externe lisse et résistante à l'usure et une partie de corps de support compressible. Le produit comprend un élément de cadre de support et la partie de corps de support est formée d'un matériau de polyuréthane microcellulaire expansible de type gel qui recouvre l'élément de cadre. La surface externe est formée d'un matériau élastomère de polyuréthane ayant une épaisseur dans la plage d'environ 0,5 mm à 0,9 mm, le matériau élastomère de polyuréthane et le matériau expansible de type gel étant collés ensemble pour former un corps complet pour le produit. L'invention propose un appareil et un procédé pour la production du produit.
PCT/CA2007/000553 2006-04-10 2007-04-03 composant de meuble à revêtement mince et procédé et appareil pour la production de celui-ci WO2007115396A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US79055806P 2006-04-10 2006-04-10
US60/790,558 2006-04-10

Publications (1)

Publication Number Publication Date
WO2007115396A1 true WO2007115396A1 (fr) 2007-10-18

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PCT/CA2007/000553 WO2007115396A1 (fr) 2006-04-10 2007-04-03 composant de meuble à revêtement mince et procédé et appareil pour la production de celui-ci

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WO (1) WO2007115396A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2919238A1 (fr) * 2007-07-25 2009-01-30 Cera Element de garnissage de siege de vehicule automobile comprenant un bloc en polyolefine expansee a face d'aspect grainee.
ITMI20091427A1 (it) * 2009-08-06 2011-02-07 Cs S R L Uso innovativo di un gel poliuretanico
EP2799203A1 (fr) * 2013-04-30 2014-11-05 Velo Enterprise Co., Ltd. Procédés de production de selles de bicyclette
CN113183386A (zh) * 2021-04-13 2021-07-30 山西凝固力新型材料股份有限公司 一种高抗压纤维增强聚氨酯复合板材及其制备方法
WO2024023717A1 (fr) * 2022-07-26 2024-02-01 Selle Royal S.P.A. Installation et procédé de fabrication d'un élément de support pour le corps humain, tel qu'une selle de véhicule

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3642400A (en) * 1969-11-06 1972-02-15 Kurt Salmon Associates Inc Apparatus for encapsulating an article within molded polyurethane
US4190697A (en) * 1979-01-15 1980-02-26 Milsco Manufacturing Company Multidensity foam article and method of preparation
US4365839A (en) * 1977-07-11 1982-12-28 Intercollection Development Sa Chair construction with protective cushioning for exposed structural projections
US4524102A (en) * 1984-02-15 1985-06-18 Fritz Hostettler Microcellular polyurethane foams having integral skin
CA2229177A1 (fr) * 1998-02-06 1999-08-06 Nightingale Inc. Appui-bras articule de fauteuil
US6861019B2 (en) * 1999-11-01 2005-03-01 Lear Corporation Method of making a fabric-less part

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3642400A (en) * 1969-11-06 1972-02-15 Kurt Salmon Associates Inc Apparatus for encapsulating an article within molded polyurethane
US4365839A (en) * 1977-07-11 1982-12-28 Intercollection Development Sa Chair construction with protective cushioning for exposed structural projections
US4190697A (en) * 1979-01-15 1980-02-26 Milsco Manufacturing Company Multidensity foam article and method of preparation
US4524102A (en) * 1984-02-15 1985-06-18 Fritz Hostettler Microcellular polyurethane foams having integral skin
CA2229177A1 (fr) * 1998-02-06 1999-08-06 Nightingale Inc. Appui-bras articule de fauteuil
US6861019B2 (en) * 1999-11-01 2005-03-01 Lear Corporation Method of making a fabric-less part

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2919238A1 (fr) * 2007-07-25 2009-01-30 Cera Element de garnissage de siege de vehicule automobile comprenant un bloc en polyolefine expansee a face d'aspect grainee.
WO2009034257A2 (fr) * 2007-07-25 2009-03-19 Centre D'etude Et De Recherche Pour L'automobile (Cera) Élément de garnissage de siège de véhicule automobile comprenant un bloc en polyoléfine expansée à face d'aspect grainée
WO2009034257A3 (fr) * 2007-07-25 2010-02-25 Centre D'etude Et De Recherche Pour L'automobile (Cera) Élément de garnissage de siège de véhicule automobile comprenant un bloc en polyoléfine expansée à face d'aspect grainée
ITMI20091427A1 (it) * 2009-08-06 2011-02-07 Cs S R L Uso innovativo di un gel poliuretanico
EP2799203A1 (fr) * 2013-04-30 2014-11-05 Velo Enterprise Co., Ltd. Procédés de production de selles de bicyclette
CN104129024A (zh) * 2013-04-30 2014-11-05 维乐工业股份有限公司 自行车座垫的制法
CN113183386A (zh) * 2021-04-13 2021-07-30 山西凝固力新型材料股份有限公司 一种高抗压纤维增强聚氨酯复合板材及其制备方法
WO2024023717A1 (fr) * 2022-07-26 2024-02-01 Selle Royal S.P.A. Installation et procédé de fabrication d'un élément de support pour le corps humain, tel qu'une selle de véhicule

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