Foaming die device for forming armrest

• US 7,798,797 B2
• Filed: 12/18/2006
• Issued: 09/21/2010
• Est. Priority Date: 12/18/2006
• Status: Expired due to Fees

• Current Assignee: Tachi-S Company Limited
• Original Assignee: Tachi-S Company Limited
• Inventors: Tabata, Tsuyoshi
• Primary Examiner(s): Griffin; Steven P
• Assistant Examiner(s): Malekzadeh; Seyed Masoud
• Application Number:
  US11/640,299
• Publication Number:
  US 20080145474A1
• Time in Patent Office: 1,373 Days
• Field of Search: 425/4.R, 425/116, 425/190, 425/192.R, 425/441, 425/392, 425/393, 425/817.R, 425/442, 425/443, 249/83, 249/85, 249/95, 249/91, 249/97, 249/170, 264/261, 264/263, 264/46.6
• US Class Current: 425/116
• 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 that allows a basic armrest unit having a connecting bracket projected outwardly from one side thereof 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 at least one through-hole (31A) formed therein, the through-hole having a circular edge portion;

a support element disposed inside of said three-dimensional trim cover assembly, said support element having two end portions, wherein at least one of said two end portions projects outwardly through said at least one through-hole of the three dimensional trim cover assembly, wherein said connecting bracket is rotatably secured to said at least one of said two end portions of said support element, and wherein, in a 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 foaming a resultant armrest having said connecting bracket provided exteriorly of one side 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 inside of both of said first and second die elements, said working die area being adapted to allow said three-dimensional trim cover assembly to be placed therein;

a recession defined in one or both of said first and second die elements so as to be recessed in a direction from said working die area into one lateral wall of at least one of the first and second die elements; and

an auxiliary die element to be accommodated in said recession, said auxiliary die element being adapted to enclose said connection bracket and slidably engage said support element, and being of a split type comprising a first die piece and a second die piece in such a manner as to be mated together, with said support element disposed therebetween, in a direction orthogonal to an axis of the support element, prior to said first and second die pieces being accommodated in said recession, so that the thus-mated first and second die pieces enclose said connecting bracket and slidably engage the support element, thereby allowing the mated first and second die pieces to be slidingly movable along said support element towards said at least one 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 at least one through-hole, and

wherein said part of said mated first and second die pieces is larger in diameter that said at least one through-hole of the three-dimensional trim cover assembly and also includes a recessed region defined in and about the outer surface thereof, said recessed region being adapted for allowing the entirety of the circular edge portion of said at least one through-hole to be fitted therein.

2. A foaming die device that allows a basic armrest unit having a connecting bracket projected outwardly from one side thereof 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 at least one through-hole (31A) formed therein, said through-hole having a circular edge portion;

a support element disposed inside said three-dimensional trim cover assembly, said support element having two end portions, wherein at least one of said two end portions projects outwardly through said at least one through-hole of the three-dimensional trim cover assembly, wherein said connecting bracket is rotatably secured to said at least one of said two end portions of said support element, and wherein, in a foaming process, a liquid foaming agent is to be injected into an inside of said three-dimensional trim cover assembly and then is cured into an increased mass of foam padding filled in the three-dimensional trim cover assembly, thereby foaming a resultant armrest having said connecting bracket provided exteriorly of one side 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 inside of both of said second and first die elements, said working die area being adapted to allow said three-dimensional trim cover assembly to be placed therein;

a recession defined in one or both of said first and second die elements so as to be recessed in a direction from said working die area into one lateral wall of at least one of the first and second die elements; and

an auxiliary die element to be accommodated in said recession, said auxiliary die element being adapted to enclose said connecting bracket and slidably engage said support element, and being of a split type,

said auxiliary die element comprising;

a first die piece having, defined therein, 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, defined therein, 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,

wherein said auxiliary die element is an arrangement such that, when said first and second die pieces are mated together, with said support element disposed therebetween, in a direction orthogonal to an axis of the support element, prior to said first and second die pieces being accommodated in said recession, the this mated first and second die pieces enclose said connecting bracket and slidably engage the support element, thereby allowing the mated first and second die pieces to be slidingly movable along said support element towards said at least one 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 at least one through-hole, and

wherein said part of said mated first and second die pieces is larger in diameter that said at least one through-hole of the three-dimensional trim cover assembly and also includes a recessed region defined in and about the outer surface thereof, said recessed region being adapted for allowing an entirety of the circular edge portion of said at least of through-hole to be fitted therein.

3. The foaming die device of claim 2, wherein said first die piece of said auxiliary die element includes a protrudent half portion having a semi-circular recessed region formed therein, and 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 in and about said columnar protrudent portion, said circular recessed region corresponding to said recessed region of said mated first and second die pieces,

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

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

4. The foaming die device of claim 2, wherein said connecting bracket has a pair of holes formed therein, and wherein a first 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, and a second 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 at least one through-hole, said first and second pins associated with the respective said first and second die pieces are displaced to and engaged in said pair of holes, respectively.