Foaming die device for forming armrest

• US 20080145474A1
• Filed: 12/18/2006
• Published: 06/19/2008
• Est. Priority Date: 12/18/2006
• Status: Active Grant

• Current Assignee: Tachi-S Company Limited
• Original Assignee: Tachi-S Company Limited
• Inventors: Tabata, Tsuyoshi
• Granted Patent: US 7,798,797 B2
• Time in Patent Office: Days
• US Class Current: 425/575
• CPC Class Codes: B29C 33/12 with incorporated means for positioning inserts, e.g. labels positioning reinforcements B29C70/541
• CPC Class Codes: B29C 44/1271 the preformed parts being partially covered
• CPC Class Codes: B29L 2031/3026 Arm-rests
• CPC Class Codes: B60N 2/7017 characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
• CPC Class Codes: B60N 2/753 movable to an inoperative position

Abstract

A foaming die device is provided, in which can be directly placed a basic armrest unit having a shaft element and a connecting bracket rotatably secured to the shaft element. The foaming die device comprises a lower die, an upper die, and an auxiliary die element of split type to be incorporated in a working die area defined by the lower and upper dies. The auxiliary die element comprises two die pieces that can be mated together so as to be in a slidable engagement about one end portion of the shaft element. Hence, the mated two die pieces or auxiliary die element is slidable along the shaft element for its partial engagement in a through-hole of the basic armrest unit, whereupon all the basic armrest unit and auxiliary die element may be directly placed in the working die area of lower and upper dies and subjected to foaming process.

Claims

1. A foaming die device of such a type that allows a basic armrest unit to be placed therein and also allows said basic armrest unit to be subjected to foaming therein, wherein said basic armrest unit comprises:

a three-dimensional trim cover assembly of a predetermined shape of armrest body;

said three-dimensional trim cover assembly including a through-hole formed therein;

a support element disposed in an inside of said three-dimensional trim cover assembly, said support element having two end portions projecting outwardly through said through-hole of the three-dimensional trim cover assembly; and

a connecting bracket rotatably secured to one of said two end portions of said support element, said connecting bracket being thus disposed exteriorly of the three-dimensional trim cover assembly, and wherein, at said foaming process, a liquid foaming agent is to be injected into the inside of said three-dimensional trim cover assembly and then cured into an increased mass of foam padding filled in the three-dimensional trim cover assembly, thereby forming a resultant armrest having said connecting bracket provided exteriorly thereof in a rotatable manner,

said foaming die device comprising;

a first die element;

a second die element movable for engagement with said first die element to define a working die area therein, said working die area being adapted to allow said three-dimensional trim cover assembly to be placed therein; and

an auxiliary die element to be incorporated in said working die area defined by said first and second die elements, said auxiliary die element being of a split type comprising a first die piece and a second die piece in such a manner as to allow said first and second die pieces to be mated together, with said support element disposed therebetween, in a direction orthogonal with an axis of the support element, so that the thus-mated first and second die pieces enclose said connecting bracket and slidably engages the support element, thereby allowing the mated first and second die pieces to be slidingly movable along said support element towards said through-hole of said three-dimensional trim cover assembly so as to allow insertion of a part of said mated first and second die pieces in said particular through-hole.

2. The foaming die device as claimed in claim 1, wherein said through-hole is of such a diameter that allows said part of said mated first and second die pieces to be inserted therethrough into the inside of said three-dimensional trim cover assembly.

3. A foaming die device of such a type that allows a basic armrest unit to be placed therein and also allows said basic armrest unit to be subjected to foaming therein, wherein said basic armrest unit comprises:

a three-dimensional trim cover assembly of a predetermined shape of armrest body;

said three-dimensional trim cover assembly including a through-hole formed therein;

a support element disposed in an inside of said three-dimensional trim cover assembly, said support element having two end portions projecting outwardly through said through-hole of the three-dimensional trim cover assembly; and

a connecting bracket rotatably secured to one of said two end portions of said support element, said connecting bracket being thus disposed exteriorly of the three-dimensional trim cover assembly, and wherein, at said foaming process, a liquid foaming agent is to be injected into the inside of said three-dimensional trim cover assembly and then cured into an increased mass of foam padding filled in the three-dimensional trim cover assembly, thereby forming a resultant armrest having said connecting bracket provided exteriorly thereof in a rotatable manner,

said foaming die device comprising;

a first die element;

a second die element movable for engagement with said first die element to define a working die area therein, said working die area being adapted to allow said three-dimensional trim cover assembly to be placed therein; and

an auxiliary die element to be incorporated in said working die area defined by said first and second die elements, said auxiliary die element being of a split type comprising;

a first die piece having;

one region for receiving one half portion of said connecting bracket therein; and

another region for slidably and substantially engaging one half of said support element; and

a second die piece having;

one region for receiving another half portion of said connecting bracket therein; and

another region for slidably and substantially engaging another half of said support element,

with such an arrangement that, when said first and second die pieces to are mated together, with said support element disposed therebetween, in a direction orthogonal with an axis of the support element, a pair of said one regions respectively of the thus-mated first and second die pieces enclose said one and another half portions of said connecting bracket, respectively, while a pair of said another regions respectively of the thus-mated first and second die pieces are brought to a slidable engagement about said one and another halves of the support element, respectively, thereby allowing the mated first and second die pieces to be slidingly movable along said support element towards said through-hole of said three-dimensional trim cover assembly so as to allow insertion of a part of said mated first and second die pieces in said particular through-hole.

4. The foaming die device as claimed in claim 3, wherein said through-hole has a circular edge portion,

wherein said first die piece of said auxiliary die element includes a protrudent half portion having a semi-circular recessed region formed therein, and, likewise, said second die piece of said auxiliary die element includes a protrudent half portion having a semi-circular recessed region formed therein, such that, when said first and second die pieces are mated together, the two protrudent half portions of the first and second die pieces are mated and matched together, thereby defining a columnar protrudent portion which corresponds to said part of said mated first and second die pieces, while at the same time, said semi-circular recessed region associated with the first die piece is mated and matched with said semi-circular recessed region associated with the second die piece, thereby defining a circular recessed region about said columnar protrudent portion,

wherein said columnar protrudent portion is slightly larger in diameter than said through-hole, and

wherein said circular recessed region is substantially identical in diameter to said through-hole, and so adapted that an entirety of said circular edge portion of said through-hole is to be engaged therein when said columnar protrudent portion is inserted in said through-hole.

5. The foaming die device as claimed in claim 3, wherein said connecting bracket has a pair of holes formed therein, and wherein a pin is formed in said one region of said first die piece so as to be in correspondence with one of said pair of holes, whereas likewise, a pin is formed in said one region of said second die piece so as to be in correspondence with another of said pair of holes, with such an arrangement that, when said mated first and second die pieces are slidingly moved along said support element towards said through-hole, said two pins associated with the respective said first and second die pieces are displaced to and engaged in said pair of holes, respectively.