Method of manufacturing reinforcing cloth of a seat pad and apparatus therefor

• US 8,926,309 B2
• Filed: 02/13/2009
• Issued: 01/06/2015
• Est. Priority Date: 03/07/2005
• Status: Active Grant

• Current Assignee: Mold Technical Office Co., Ltd., Toyota Tsusho Corporation
• Original Assignee: Mold Technical Office Co., Ltd., Nitto Boseki Company Limited, Toyota Tsusho Corporation
• Inventors: Shimada, Masanori, Wakamatsu, Koji, Iwasawa, Toshio, Ishida, Shunpei, Nakano, Minoru
• Primary Examiner(s): SANDERS, JAMES M
• Application Number:
  US12/370,678
• Publication Number:
  US 20090191298A1
• Time in Patent Office: 2,153 Days
• Field of Search: 425/387.1, 425/389, 425/469, 425/403, 425/504, 425/508, 425/405.1
• US Class Current: 425/387.1
• CPC Class Codes: B29C 2043/3644 Vacuum bags; Details thereof, e.g. fixing or clamping
• CPC Class Codes: B29C 2791/006 Using vacuum
• CPC Class Codes: B29C 35/045 using gas or flames
• CPC Class Codes: B29C 35/049 using steam or damp
• CPC Class Codes: B29C 43/10 Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
• CPC Class Codes: B29C 51/004 Textile or other fibrous material made from plastics fibres combined with plastic layers B29C51/145; compression moulding of reinforced plastic articles in matched moulds B29C70/46; using pressure difference B29C70/44
• CPC Class Codes: B29C 51/10 Forming by pressure difference, e.g. vacuum
• CPC Class Codes: B29C 51/28 for applying pressure through the wall of an inflated bag or diaphragm
• CPC Class Codes: B29K 2105/0854 in the form of a non-woven mat
• CPC Class Codes: B29L 2031/30 Vehicles, e.g. ships or aircraft, or body parts thereof vanes or blades B29L2031/08, air bags B29L2022/027
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B29L 2031/771 Seats
• CPC Class Codes: B60N 2/5875 by adhesion, e.g. gluing
• CPC Class Codes: B60N 2/7017 characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
• CPC Class Codes: D04H 1/005 Making three-dimensional articles by consolidation D04H1/22 takes precedence

Abstract

An apparatus for manufacturing a reinforcing cloth of a seat pad which includes: a mold for fixing a sheet and having an outer shape substantially identical to a shape of the reinforcing cloth and provided with a plurality of air holes interconnecting an internal space with an outer surface; a closed space between the mold and a cover member formed by covering the sheet fixed on the mold with the cover member; a heating unit for heating the sheet; and an exhausting unit for exhausting air from the closed space is provided.

Claims

1. An apparatus for manufacturing a reinforcing cloth of a seat pad, the apparatus comprising:

a mold with an internal space for fixing a sheet, formed as a hollow shell of a single material, the mold having an outer shape that is substantially identical to a shape of the reinforcing cloth, the mold including a plurality of air holes provided through the shell, the air holes interconnecting the internal space with an outer surface of the mold;

a cover member formed of a bag-shaped film, for forming a closed space inside thereof by covering the mold, the cover member being removable from the sheet after molding the sheet into a shape;

a heating unit for heating the sheet; and

an exhausting unit for exhausting air from the closed space,

wherein the heating unit supplies heated air to the closed space through the air holes of the mold by supplying the heated air to the internal space of the mold and the exhausting unit exhausts air from the closed space through the air holes of the mold,

wherein the cover member is capable of deflating to be sucked by the mold so that the sheet is deformed to be sucked and comes into close contact with the mold when the air in the closed space is exhausted by the exhausting unit, and

wherein a contour of an inner surface of the mold and a contour of an outer surface of the mold is substantially similar.

7. The apparatus according to claim 1,

wherein the cover member includes a main layer with air-tightness and a reinforcing layer with tensile strength higher than that of the main layer, and

wherein the reinforcing layer is disposed on a surface of the main layer at a side where the cover member makes contact with the mold.

8. The apparatus according to claim 7,

wherein the reinforcing layer is made of expandable raw materials in knit form.

13. The apparatus for manufacturing a reinforcing cloth of a seat pad according to claim 1, wherein the mold has a front portion and a rear portion opposed to the front portion with the internal space in between, and the front portion and the rear portion are provided with the air holes.

14. The apparatus for manufacturing a reinforcing cloth of a seat pad according to claim 1, wherein there are more numbers of the air holes formed in the corner portions of the mold than in the remaining portions of the mold.

15. The apparatus for manufacturing a reinforcing cloth of a seat pad according to claim 1, wherein a volume of the internal space is bigger than a volume of the shell of the mold.

16. The apparatus for manufacturing a reinforcing cloth of a seat pad according to claim 1, further comprising:

a base for mounting the mold; and

a hollow leg erected from the base and attached to the mold,

wherein the heated air is supplied to the internal space of the mold through the base and the hollow leg while air in the internal space of the mold is exhausted through the hollow leg and the base.

17. The apparatus for manufacturing a reinforcing cloth of a seat pad according to claim 16,

wherein the cover member is configured to cover the mold and be fixed to the base to form the closed space inside thereof.

18. The apparatus for manufacturing a reinforcing cloth of a seat pad according to claim 16,

wherein the cover member is configured to cover the mold and be fixed to the hollow leg to form the closed space inside thereof.

2. An apparatus for manufacturing a reinforcing cloth of a seat pad, the apparatus comprising:

a mold for fixing a sheet, the mold having an outer shape substantially identical to a shape of the reinforcing cloth and provided with a plurality of air holes interconnecting an internal space with an outer surface;

a cover member formed of a bag-shaped film, for forming a closed space inside thereof by covering the mold;

a heating unit for heating the sheet; and

an exhausting unit for exhausting air from the closed space,

wherein the heating unit supplies heated air to the closed space through the air holes of the mold by supplying the heated air to the internal space of the mold and the exhausting unit exhausts air from the closed space through the air holes of the mold, and

wherein the closed space is formed by at least the mold, the cover member, and the cover frame, and

wherein the cover frame includes a pair of movable frames capable of being separated in a horizontal direction, and the cover member is fixed to each of the movable frames.

3. The apparatus according to claim 2,

wherein the movable frame includes a duct interconnecting the inside and the outside of the closed space.

4. An apparatus for manufacturing a reinforcing cloth of a seat pad, the apparatus comprising:

a mold for fixing a sheet, the mold having an outer shape substantially identical to a shape of the reinforcing cloth and provided with a plurality of air holes interconnecting an internal space with an outer surface;

a cover member forming a closed space inside thereof by covering the mold;

a heating unit for heating the sheet; and

an exhausting unit for exhausting air from the closed space,

wherein the heating unit supplies heated air to the closed space through the air holes of the mold by supplying the heated air to the internal space of the mold and the exhausting unit exhausts air from the closed space through the air holes of the mold, and

wherein the cover member has a pleat portion in a state before air in the closed space is exhausted.

5. The apparatus according to claim 4,

wherein the cover member includes an elastic cord so as to maintain a shape of the pleat portion.

6. The apparatus according to claim 5,

wherein the elastic cord is fixed to the cover member so as to intersect the pleat portion.

9. An apparatus for manufacturing a reinforcing cloth of a seat pad, the apparatus comprising:

a mold for fixing a sheet, the mold having an outer shape substantially identical to a shape of the reinforcing cloth and provided with a plurality of air holes interconnecting an internal space with an outer surface;

a cover member forming a closed space inside thereof by covering the mold;

a heating unit for heating the sheet; and

an exhausting unit for exhausting air from the closed space,

further comprising a cover frame to enclose the mold and to which the cover member is fixed,

wherein the closed space is formed by at least the mold, the cover member, and the cover frame; and

wherein the cover frame includes a pair of movable frames capable of being separated in a horizontal direction, and the cover member is fixed to each of the movable frames.

10. The apparatus according to claim 9,

wherein the movable frame includes a duct interconnecting the inside and the outside of the closed space.

11. An apparatus for manufacturing a reinforcing cloth of a seat pad, the apparatus comprising:

a mold for fixing a sheet, the mold having an outer shape substantially identical to a shape of the reinforcing cloth and provided with a plurality of air holes interconnecting an internal space with an outer surface;

a cover member forming a closed space inside thereof by covering the mold;

a heating unit for heating the sheet; and

an exhausting unit for exhausting air from the closed space,

wherein the cover member has a pleat portion in a state before air in the closed space is exhausted, and

wherein the cover member includes an elastic cord so as to maintain a shape of the pleat portion.

12. The apparatus according to claim 11,

wherein the elastic cord is fixed to the cover member so as to intersect the pleat portion.