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    • 专利摘要:
    FOAM SEATING ELEMENT, AND PROCESS AND TEMPLATE TO PRODUCE THE SAME. A padded element comprising a foam substrate having a first inner surface and a second inner surface opposite to the first inner surface, the first inner surface being interposed between an outer surface of the foam substrate and the second inner surface, is described. minus one of the first inner surface and the second inner surface comprising a textured part. In a highly preferred embodiment, the pair of internal surfaces, arranged within the foam substrate body, combine to form one or more cavities in the foam substrate (for example, by providing an inner surface having a textured part and the other surface not being textured). The provision of such a textured surface creates a contact interface (both at rest and when an occupant is seated in the seat) between below or away from the A-surface of the foam element. This interface has different properties than the exposed surface of the seat element. Adopting this approach of internal interface for one or more zones of foam element, it is possible to confer different qualities of comfort and sensation on the external surface of the (...) element.
    公开号:BR112014000464B1
    申请号:R112014000464-1
    申请日:2012-07-16
    公开日:2021-02-02
    发明作者:Pasquale Rossi；Edgardo A. San Miguel
    申请人:Proprietect L.P；
    IPC主号:
    专利说明:

    Cross-reference with related order
    [001] The present application claims the benefit under 35 U.S.C. §119 (e) of the provisional patent application S.N. 61 / 457,943, filed on July 14, 2011, the contents of which are incorporated by reference. Field of invention
    [002] In one of its aspects, the present invention relates to a foam seat element, preferably a foam vehicle seat element. In another aspect, the present invention relates to a process for producing a foam seat element, preferably a vehicle seat element. In yet another aspect, the present invention relates to a mold for producing a molded element, preferably a molded foam seat element, more preferably a molded foam vehicle seat element. Description of the Prior Art
    [003] Passenger seats in vehicles, such as automobiles, are typically manufactured from a foam (usually a polyurethane foam) that is molded to the desired shape and covered with a finish cover. The foam material is selected to provide passenger comfort by providing a resilient seat and the finishing cover is selected to provide the desired aesthetic properties.
    [004] In recent years, seats such as vehicle seats have been developed to provide one or more of the following for the seat: comfort, climate control, occupant detection and the like.
    [005] One area that has received particular attention is the provision of double density or double firmness seat components that are denser or firmer in the peripheral parts of the seat thereby giving the occupant a pleasant or enveloping feeling. This is especially important in performance vehicles that are designed so that relatively high speed cornering can be achieved. However, there is a constant challenge to balance the support provided by the seat with occupant comfort.
    [006] Double density or double firmness seat elements are expensive to produce and, in many cases, change the feel of the seat support surface only in areas where it is perceived to be important to have different firmness properties. In other words, conventional double density or double firmness seat elements generally use a generally coarse approach to the provision of variable density or firmness.
    [007] Additionally, double density (or multiple) or double firmness (or multiple) seats typically require the use of two or more types of foam (for example, molded, free-expanding, granule and the like) that are typically produced separately and stuck together increasing the time and cost of producing the final seat product. Alternatively, certain double (or multiple) seats are made by molding or otherwise holding an insert (for example, wire components, FLEXOLATORS, and the like) on a foam substrate.
    [008] International Publication N °. WO 2006/102751 [San Miguel et al. (San Miguel)] shows a foam seat element, a mold for producing it and a method for making the mold. The foam seating element shown by San Miguel comprises a seating surface on which one or more textured surfaces, the same or different, are created. The provision of such textured surfaces makes possible in a single density part of the comfort of "double firmness" (or multiple firmnesses) or sensation that is conveniently achieved by using pieces of foam of multiple densities in a seat element. One of the advantages of the San Miguel approach is that it is possible to give the seat element a soft feel as an alternative to the so-called conventional additional upholstery.
    [009] While the teachings in San Miguel represent an advance in technique, there is still room for improvement.
    [010] Specifically, when applying San Miguel's teachings to vehicle car seats, it is conventional to create one or more texturized surfaces on the so-called A vehicle seat surface. In doing so, there is a likelihood that the textured surface can be felt or seen through the finish cover (leather or lining) used to cover the foam seat element - this is also known in the art as "read through". Automotive companies have continuously increased specifications and requirements for fitting and terminating vehicle seats and the occurrence of “read through” on a vehicle seat is considered a disadvantage.
    [011] Consequently, it would be desirable to have a foam element that, on the one hand, maintains San Miguel's technical advantage (ie, the ability to have different comfort zones or feel on a foam element surface while using a foam element). single density foam) while, on the other hand, prevents or mitigates the occurrence of “read through” on an A surface of the foam element when it is adapted for vehicle seats.
    [012] It would be particularly advantageous if such an improvement could be implemented without requiring large capital expenditure. Summary of the invention
    [013] It is an objective of the present invention to avoid or mitigate at least one of the above mentioned disadvantages of the prior art.
    [014] Consequently, in one of its aspects, the present invention provides a padded element comprising a foam substrate having a first inner surface and a second inner surface opposite to the first inner surface, the first inner surface being interposed between a outer surface of the foam substrate and the second inner surface, at least one of the first inner surface and the second inner surface comprising a textured part.
    [015] In another aspect, the present invention provides a mold for producing a molded element, the mold comprising a first mold part and a second interlockable mold part to define a mold cavity, the mold still comprising at least an insertion element having a textured surface and configured to create a first inner surface and a second inner surface opposite each other in a molded element.
    [016] In a preferred embodiment, the padded element is comprised of a seat element. In this embodiment, the seat element preferably comprises a molded foam seat element, more preferably, a molded foam element comprising a unitary foam part. An advantage of using such a molded foam element on the present seat element is the presence of a lining on the surface of one or both of the first inner surface and the second inner surface. The presence of the lining is characterized by the internal surface (first and / or second) having a higher density on the surface (for example, 1 mm in depth) when compared to the central or core region away from the internal surface. The density can be determined using ASTM D-3574. While it is not desired to be limited by any particular theory or mode of action, it is believed that the presence of such a lining (for example, as distinct from the case where the peaks are simply glued on and / or the valleys are simply cut out of the element seat surface) provides a desirable combination of support and comfort for an occupant of the seat element.
    [017] Thus, the present inventors have discovered an approach by which it is possible to obtain the benefits described in San Miguel while preventing or mitigating the occurrence of "read through". Specifically, in the padded element present in the form of a seat element, an internal interface is created between a pair of internal surfaces arranged within with the body of the foam substrate, where at least one of the internal surfaces is textured. In a highly preferred embodiment, the pair of internal surfaces, arranged within the foam substrate body, combine to form one or more cavities in the foam substrate (for example, by providing an inner surface having a textured part and the other surface not being textured). The provision of such a textured surface creates a contact interface (both at rest and when an occupant is seated in the seat) between below or away from the A-surface of the foam element. This interface has different properties than the exposed surface of the seat element. By adopting this approach of internal interface for one or more zones of foam element, it is possible to confer different qualities of comfort and sensation on the outer surface of the foam element (for example, the A-surface of a vehicle seat element) although the appearance of this outer surface may be relatively non-textured. In this way, the occurrence of “read through” described above is avoided or mitigated.
    [018] A number of different modalities can be used to adopt this approach.
    [019] First, it is possible to have a foam seat element that is a separate part from the foam substrate. Alternatively, it is possible to have the foam seat part created with the foam substrate in a single mold resulting in the production of a so-called foldable construction that allows the use of a single tool to produce the entire foam element (compared to the first modality that requires separate tools to produce the foam seat element and the foam substrate). Both of these modalities allow the use of a substantially complementary pair of internal surfaces on the foam seat element and foam substrate.
    [020] A particularly preferred alternative embodiment refers to the use of a mold having one or more tongue elements (or inserts) that produce the above-mentioned interface in situ in a single piece of foam. An advantage of this approach is that tooling and manufacturing (rework) costs are optimized. In addition, the tongue element can be adapted to existing molds in this way allowing the implementation of the present invention without the need to build custom molds and incur associated capital costs.
    [021] The foam element containing the first inner surface and the second inner surface described above can be the same or different, regardless of whether the foam element is a single piece of foam or the first inner surface and the second inner surface are comprised of separate pieces of foam. If the foam element containing the first inner surface and the second inner surface described above is different, it can be obtained by pouring different formulations into the foam. Preferably, the result is in foam elements for the first inner surface and the second inner foam surface that differ with respect to one or more of the following: density, hardness, indentation force deflection, sound absorption, transmission loss sound, hysteresis, tensile strength and combinations of two or more of these.
    [022] Of course, those skilled in the art will recognize other benefits from the present seating element based on the present report. Brief description of the drawings
    [023] Modalities of the present invention will be described with reference to the accompanying drawings, in which equal reference numerals indicate equal parts, and in which: Figure 1 illustrates a perspective view of a first embodiment of the seat element of the present invention; Figure 2 shows a sectional view of the seat element shown in Figure 1; Figure 3 shows an enlarged part of the seat element shown in Figure 2; Figure 4 illustrates a second embodiment of the seat element of the present invention; Figure 5 shows a sectional view of the seat element shown in Figure 4; Figure 6 illustrates the production of the final seat element shown in Figure 4; Figure 7 illustrates a perspective view of a mold suitable for use in producing a third embodiment of the seat element of the present invention; Figures 8-12 illustrate in sequence the production of the third embodiment of the seat element of the present invention using the mold shown in Figure 7; Figures 13-14 illustrate a modification of the mold and seat element shown in Figures 7-12; and Figure 15 illustrates a sectional view of a seat element according to the third embodiment of the present invention. Detailed description of preferred modalities
    [024] Modalities of the present invention will be described with reference to the accompanying drawings, in which equal reference numerals indicate equal parts, and in which: in one of its aspects, the present invention refers to a padded element comprising a foam substrate having a first inner surface and a second inner surface opposite to the first inner surface, the first inner surface being interposed between an outer surface of the foam substrate and the second inner surface, at least one of the first inner surface and the second inner surface comprising a textured part. Preferred embodiments of the padded element can include any one or a combination of two or more of any of the following: - the first inner surface comprises a textured part and the second inner surface is substantially non-textured; - the first inner surface is substantially non-textured and the second inner surface comprises a textured part; - the first inner surface and the second inner surface comprise a textured part; - the first inner surface and the second inner surface are in a spaced relationship in a resting position of the padded element; - the first inner surface and the second inner surface are in a contact relationship in a resting position of the padded element; - the foam substrate is molded; - the foam substrate is molded from a unitary foam part; the textured part comprises a plurality of peak parts and a plurality of valley parts; - each peak part comprises an apex part; - the apex part comprises a first pointed part; - the apex part comprises a first rounded part; - the apex part comprises a first flat part; - each part of the valley comprises a nadir part; - the nadir part comprises a second pointed part; - the nadir part comprises a second rounded part; - the nadir part comprises a second flat part; - each peak part comprises an apex part and each valley part comprises a nadir part; - the apex part and the nadir part comprise the same profile; - the apex part and the nadir part comprise a different profile; - the apex part comprises a first pointed part; - the apex part comprises a first rounded part; - the apex part comprises a first flat part; - the nadir part comprises a second pointed part; - the nadir part comprises a second rounded part; - the nadir part comprises a second flat part; - each peak part in the plurality of peak parts is substantially elongated; - the plurality of peak parts are arranged substantially parallel to each other; - each valley part in the plurality of valley parts is substantially elongated; - the plurality of peak parts comprise a first series of elongated peak parts and a second series of elongated peak parts, the first series and the second series being arranged transversely to one another; - the plurality of peak parts comprise a first series of elongated peak parts and a second series of elongated peak parts, the first series and the second series being arranged not parallel to each other; - the plurality of peak parts comprise a first series of elongated peak parts and a second series of elongated peak parts, the first series and the second series being arranged orthogonal to each other; the plurality of valley parts comprise a first series of elongated valley parts and a second series of elongated valley parts, the first series and the second series being arranged transversely to one another; the plurality of valley parts comprise a first series of elongated valley parts and a second series of elongated valley parts, the first series and the second series being arranged not parallel to each other; the plurality of valley parts comprise a first series of elongated valley parts and a second series of elongated valley parts, the first series and the second series being arranged orthogonal to each other; - each peak part in the plurality of peak parts is substantially elongated and each valley part in the plurality of valley parts is substantially elongated; - the plurality of peak parts and the plurality of valley parts are arranged in a substantially parallel relationship; - the plurality of peak parts are comprised in a plurality of substantially vertical projections; - a cross section of each projection comprises a rectangle; - a cross section of each projection comprises a trapezoid; - a cross section of each projection comprises a symmetrical trapezoid bilaterally; - a cross section of each projection comprises a pointed shape; - a cross section of each projection comprises a shell shape; - a cross section of valley parts between adjacent projections comprises a shell shape; - each projection comprises a cloister arch shape; - the plurality of projections comprise substantially the same format; - the plurality of projections comprise substantially the same dimension; - the plurality of projections comprise substantially the same format and the same dimension; - the plurality of projections comprise different formats; - the plurality of projections comprise different dimensions; - the plurality of projections comprise different formats and different dimensions; - the plurality of projections comprise substantially the same different shape and dimensions; - the plurality of projections comprise different formats and the same dimension; - at least two parts of the valley are interconnected; - the plurality of valley parts are interconnected; - at least two parts of the valley are independent of each other; - the plurality of valley parts are independent of each other; - at least two peak parts are interconnected; - the plurality of peak parts are interconnected; - at least two peak parts are independent of each other; - the plurality of peak parts are independent of each other; - the textured part comprises a first corrugated pattern; - the textured part comprises a first corrugated pattern and a second corrugated pattern arranged in transversal relation with respect to each other; - the textured part comprises a first corrugated pattern and a second corrugated pattern arranged in orthogonal relation with respect to each other; - the textured part comprises a first toothed pattern; the textured part comprises a first toothed pattern and a second toothed pattern arranged in a transverse relationship with respect to each other; the textured part comprises a first toothed pattern and a second toothed pattern arranged in an orthogonal relationship with respect to each other; the seating surface element comprises a plurality of sections, each section comprising a plurality of peak parts and a plurality of valley parts; - the plurality of peak parts in each section are the same; - the plurality of valley shares in each section are the same; - the plurality of peak parts and the plurality of valley parts in each section are the same; - the plurality of peak parts in each section are different; - the plurality of valley parts in each section are different; - the plurality of peak parts and the plurality of valley parts in each section are different; the padded element further comprises at least one groove that separates at least part of a pair of adjacent sections from the plurality of sections; - the foam substrate comprises an isocyanate-based foam; - the foam substrate comprises a polyurethane foam; - the foam substrate comprises a polyolefin-based foam; - the foam substrate comprises a polypropylene foam; - the foam substrate comprises a polyethylene foam; - the foam substrate comprises a uniform density; and / or - the foam substrate comprises a variable density.
    [025] In a preferred embodiment, the padded element is in the form of a seat element. In this preferred embodiment, it is still preferred that the seating element comprises a portion of the seating surface having the outer surface and the first inner surface.
    [026] In an even more preferred embodiment, the present invention relates to a vehicle seat comprising the seat element mentioned above. This includes a vehicle seat bottom, a vehicle seat or a complete vehicle seat comprising both.
    [027] In another aspect, the present invention relates to a mold for producing a molded element, the mold comprising a first mold part and a second moldable part interlockable to define a mold cavity, the mold still comprising at least one insert element having a textured surface and configured to create an opposing first inner surface and second inner surface in the molded element. Preferred embodiments of the mold can include any one or a combination of two or more of the following aspects: - the textured surface comprises a plurality of peak parts and a plurality of valley parts; - each peak part comprises an apex part; - the apex part comprises a first pointed part; - the apex part comprises a first rounded part; - the apex part comprises a first flat part; - each part of the valley comprises a nadir part; - the nadir part comprises a second pointed part; - the nadir part comprises a second rounded part; - the nadir part comprises a second flat part; - each peak comprises an apex part and each of the valley comprises a nadir part; - the apex part and the nadir part comprise the same profile; - the apex part and the nadir part comprise a different profile; - the apex part comprises a first pointed part; - the apex part comprises a first rounded part; - the apex part comprises a first flat part; - the nadir part comprises a second pointed part; - the nadir part comprises a second rounded part; - the nadir part comprises a second flat part; - each peak part in the plurality of peak parts is substantially elongated; - the plurality of peak parts are arranged substantially parallel to each other; - each valley part in the plurality of valley parts is substantially elongated; - the plurality of peak parts comprise a first series of elongated peak parts and a second series of elongated peak parts, the first series and the second series being arranged transversely to one another; - the plurality of peak parts comprise a first series of elongated peak parts and a second series of elongated peak parts, the first series and the second series being arranged not parallel to each other; - the plurality of peak parts comprise a first series of elongated peak parts and a second series of elongated peak parts, the first series and the second series being arranged orthogonal to each other; the plurality of valley parts comprise a first series of elongated valley parts and a second series of elongated valley parts, the first series and the second series being arranged transversely to one another; the plurality of valley parts comprise a first series of elongated valley parts and a second series of elongated valley parts, the first series and the second series being arranged not parallel to each other; the plurality of valley parts comprise a first series of elongated valley parts and a second series of elongated valley parts, the first series and the second series being arranged orthogonal to each other; - each peak part in the plurality of peak parts is substantially elongated and each valley part in the plurality of valley parts is substantially elongated; - the plurality of peak parts and the plurality of valley parts are arranged in a substantially parallel relationship; - the plurality of peak parts are comprised in a plurality of substantially vertical projections; - a cross section of each projection comprises a rectangle; - a cross section of each projection comprises a trapezoid; - a cross section of each projection comprises a symmetrical trapezoid bilaterally; - a cross section of each projection comprises a pointed shape; - a cross section of each projection comprises a shell shape; - a cross section of valley parts between adjacent projections comprises a shell shape; - each projection comprises a cloister arch shape; - the plurality of projections comprise substantially the same format; - the plurality of projections comprise substantially the same dimension; - the plurality of projections comprise substantially the same format and the same dimension; - the plurality of projections comprise different formats; - the plurality of projections comprise different dimensions; - the plurality of projections comprise different formats and different dimensions; - the plurality of projections comprise substantially the same different shape and dimensions; - the plurality of projections comprise different formats and the same dimension; - at least two parts of the valley are interconnected; - the plurality of valley parts are interconnected; - at least two parts of the valley are independent of each other; - the plurality of valley parts are independent of each other; - at least two peak parts are interconnected; - the plurality of peak parts are interconnected; - at least two peak parts are independent of each other; - the plurality of peak parts are independent of each other; - the seat surface molding element comprises a first corrugated pattern; - the seat surface molding element comprises a first corrugated pattern and a second corrugated pattern arranged in a transverse relationship with respect to each other; the seat surface molding element comprises a first corrugated pattern and a second corrugated pattern arranged in an orthogonal relationship with respect to each other; - the seat surface molding element comprises a first toothed pattern; the seat surface molding element comprises a first toothed pattern and a second toothed pattern arranged in a transverse relationship with respect to each other; the seat surface molding element comprises a first toothed pattern and a second toothed pattern arranged in an orthogonal relationship with respect to each other; the seating surface element comprises a plurality of sections, each section comprising a plurality of peak parts and a plurality of valley parts; - the plurality of peak parts in each section are the same; - the plurality of valley shares in each section are the same; - the plurality of peak parts and the plurality of valley parts in each section are the same; - the plurality of peak parts in each section are different; - the plurality of valley parts in each section are different; - the plurality of peak parts and the plurality of valley parts in each section are different; - the at least one insertion element is affixed to one of the first mold part and the second mold part; - the at least one insertion element is movable with respect to one or both of the first mold part and second mold part to facilitate the demolding of the molded element; - the at least one insertion element is pivotally movable with respect to one or both of the first mold part and second mold part to facilitate the demoulding of the molded element; - the first mold part is a lid and the second mold part is a cup; - the at least one insertion element is affixed to the bowl; - the at least one insertion element is movable with respect to the cup to facilitate demoulding of the molded element; - the at least one insertion element is pivotally movable with respect to the bowl to facilitate the demoulding of the molded element; and / or - the mold comprises a plurality of insertion elements, each insertion element comprising a textured surface.
    [028] In another aspect, the present invention relates to a process for producing a molded element as described above, the process comprising the steps of: - i) distributing a moldable composition in the mold cavity; - ii) substantially completely cover the at least one insertion element with the moldable composition; and - iii) curing the moldable composition to produce the molded element.
    [029] In another aspect, the present invention relates to the process for producing a foam element described above, the process comprising the steps of: (i) distributing a foam forming composition in the mold cavity; (ii) expand the foaming composition; and (iii) substantially completely cover the at least one insertion element with the foaming composition.
    [030] Preferably, the foam-producing composition is a liquid. More preferably, the foaming composition comprises a foaming polyurethane composition.
    [031] In the aspects of the aforementioned process of the present invention, it is preferred that the foam element is a seat element, more preferably, a vehicle seat bottom, a vehicle seat back or a vehicle seat comprising the combination thereof.
    [032] Consequently, a highly preferred aspect of the present invention relates to a seat element. Preferably, a seat element is comprised of a vehicle or passenger seat. As used throughout this report, the term “seat” is intended to have its conventional meaning and includes one of a bottom or cushion (that is, the part of the seat on which the occupant sits) and a back or back (that is, the part of the seat that supports the occupant's back). As is known in the automotive, aeronautical and related industries, a “seat” includes a cushion (or bottom) and a back (or back). Thus, the term "seat" includes a seat element such as a cushion (or bottom) and a back (or back) or a unitary construction comprising a cushion (or bottom) and a back (or back). It should also be mentioned that a seat element can be considered to be a cushion (or bottom), a back (or back), a headrest and / or an armrest.
    [033] While the highly preferred embodiments of the present invention will be illustrated with reference to a vehicle seat element, in particular a seat cushion (or bottom), it will be appreciated that the present seat element can be used in non-vehicle applications such as residential and office furniture, stadium seats, theater seats and the like.
    [034] With reference to Figures 1-3, a seat element 100 is illustrated.
    [035] The seat element 100 comprises a foam substrate 105. The foam element 105 can be made of conventional foam materials, such as polyurethane foam and the like.
    [036] The foam substrate 105 comprises a recess 110 disposed in a central region thereof. The bottom surface of this recess has a textured part 115. In the illustrated embodiment, the textured part 115 has a series of elongated grooves defined by a number of flat peaks and flat valleys.
    [037] The foam substrate 100 can be produced in a conventional manner - see, for example, San Miguel described above.
    [038] As described above, it is preferred that the foam substrate 105 is a molded foam, more preferably made of polyurethane. In this preferred embodiment, the textured part 115 would have the coated surface described above.
    [039] As shown in figure 1, a seat surface portion 120 is arranged above the foam substrate 105.
    [040] The seat surface part 120 can be produced independently of the foam substrate 105 and can be made of conventional foam materials such as polyurethane foam and the like.
    [041] It is possible to produce the seat surface part 120 from the same or different foam as the foam substrate 105. Additionally, it is possible that the seat surface part 120 and the foam substrate 105 may have the same densities or different. The underside of the seat surface part 120 comprises a textured surface 125. In this preferred embodiment, the textured part 125 would have the coated surface described above.
    [042] Preferably, the textured surface 115 and the textured surface 125 are substantially complementary.
    [043] With continuous reference to Figure 1, when it is desired to produce the seat element 100, the seat surface part 120 is lowered in the direction of the arrow A such that a "fit" is created between the textured surface 115 and the surface textured 125 - see Figure 2. In Figure 2, an interface 130 is created between textured surfaces 115, 125. This interface is below the A-surface of the seat element 100 while, in the illustrated embodiment, the current A-surface is relatively small. not textured. Once the seat element 100 is covered, the occurrence of "read through" is avoided or mitigated. Advantageously, the interface provision 130 below the A-surface of the seat element 100 provides a firmer feel in the central part 110 of the seat element when compared to the outer parts of the seat element 100.
    [044] Of course, those skilled in the art will understand that it is possible to use different shapes for the cross section of textured surfaces 115, 125 to modify the type of comfort and feel conferred on the seat element 100. It is also possible to use more than one like this called the zone with the internal interface created below the A-surface of the foam to provide different comfort and feel zones on the seat element 100. In this respect, all the textured surfaces described in San Miguel can be used on the seat element 100 using the approach to interface between the foam substrate 105 and the seat surface part 120 which is below the A-surface of the seat element 100.
    [045] With reference to Figures 4-6, the seat element 200 is illustrated.
    [046] In Figure 4-6, reference numerals having the same last two digits as reference numerals that appear in Figures 1-3 are intended to indicate similar parts.
    [047] The biggest difference between the seat element 100 shown in Figures 1-3 and the seat element shown in Figures 4-6 is that the seat surface part 220 on the seat element 200 is fixed on the foam substrate 205 by a connection part 250.
    [048] It will be apparent to those skilled in the art that an advantage of the seat element 200 is that it can be produced in a single mold in this way avoiding the increased costs associated with the production of the seat element 100.
    [049] The choice of materials for the foam substrate 205 and the seat surface part 220 described above with reference to the seat element 100 applies to the seat element 200.
    [050] Similarly, textured surfaces 215, 225 can be selected using the same approach described above with reference to seat element 100.
    [051] When it is desired to produce the seat element 200, the seat surface part 220 is folded in the direction of arrow B - see Figures 4 and 6. Since the seat surface part 220 is completely folded and fits into the recessed part 210 of the foam substrate 205 in a manner where the textured surfaces 215, 225 are incorporated to form an interface as described above with reference to the seat element 100.
    [052] As can be seen in Figures 1-6, that the interface between the textured surface 115, 125 of the foam substrate 105, 205 and the textured surface 125, 225 of the seat surface part 120, 220 is substantially complementary . While this is preferred, it is possible to select formats that strictly speaking are not complementary, but create a so-called interference or friction fit. The point is that the shapes of fabricated surfaces 115, 215 of foam substrate 105, 205 and 125, 225 of the seat surface part 120, 220 must be selected in order to hold the pieces together until a finishing cover can be applied to the seat element 100, 200.
    [053] With reference to Figure 7, a seat element 300 is illustrated. The seat element 300 comprises a surface-A 305 and a surface-B 310 opposite the surface-A 305. As can be seen, the surface -A is relatively non-textured.
    [054] The seating element 300 comprises a foam substrate 315. As shown, the foam substrate 315 comprises a cavity 320 comprised of a textured inner surface 325 in spaced relation with respect to an inner non-textured surface 330.
    [055] The textured inner surface 325 consists of a series of peaks 327 and valleys 329. In this respect, the convention used is a "peak" is directed to cavity 320 while a "valley" is directed away from cavity 320.
    [056] In this illustrated embodiment, in a resting state of the seat element 300 (that is, a state in which no occupant is seated on the seat element 300), the peaks 327 of textured inner surface 325 do not contact the inner surface not textured 330. It should be understood by those skilled in the art that it is possible to modify the seating element 300 so that the peaks 327 of the textured inner surface 325 are in contact with the non-textured inner surface 330 even if no occupant is sitting on the textured element. seat 300.
    [057] The seat element 300 is a particularly preferred embodiment of the padded element present. In this regard, it should be noted that the provision of the textured inner surface 325 in the cavity 320 of the foam substrate 315 provides improved comfort of the seat element 300 while preventing or mitigating the occurrence of "read through" described above (for example, compared with placing the textured surface directly on the A-surface 305). In this respect, the precise texture pattern can be modified and different zones of different textures can be used to give different comfort and feel on the A-surface 305 when an occupant sits on the seat element 300 - see, for example San Miguel described above for a description of several examples of textured surfaces that can be used.
    [058] As illustrated, the seat element 300 is made of a unitary foam substrate 315 - this is a preferred embodiment of the padded element present. Of course, it is possible to modify this illustrated modality by coupling different foam elements or using the so-called flap-over approach as described above with reference to Figures 1-3 and 4-6, respectively.
    [059] With reference to Figures 8-13, a mold 400 is illustrated for producing seat element 300. Thus, the mold 400 comprises a lid 405 and a bowl 410. As illustrated particularly in Figures 9 and 10, the lid 405 and cup 410 are coupled in a pivoting arrangement by means of a hinge 407 (or other suitable means) between an open position (Figure 9) and a closed position (Figure 10). In closed mold 400, a mold cavity 420 is defined.
    [060] As shown in Figures 9 and 10, an insertion element 415 is mounted on the cup 410 by means of a pivot element 417. The insertion element 415 comprises a textured surface 420 and a flatter surface 430. The textured surface 420 comprises a series of elongated groove elements 422. Adjacent pairs of elongated groove elements 422 are separate valley parts 424.
    [061] Figures 11-13 illustrate, in sequential manner, production of the padded element such as seat element 300 illustrated in Figure 7. Thus, in an initial step, a foam-forming composition is distributed from a suitable nozzle 403 ( Figure 8) in the bowl 410. The lid 405 and the bowl 410 are closed and the foaming composition is expanded to fill the mold cavity 409, as shown in Figure 11 to produce a portion of foam 440.
    [062] Next, with reference to Figure 12, the cover 405 is opened. Approximately at the same time, the insertion element 415 is also pivoted in an upward direction to the lid 403, as shown in Figure 12. The foam portion 440 is then removed from the mold 400 in the direction of arrow A.
    [063] The foam part 440 shown in Figure 13 after it has been removed from mold 400. The peak parts 427 are shown inside the foam part 440 and represent foam that fills the valley parts 424 between the elongated groove elements 422 of the insertion element 415.
    [064] With reference to Figures 14 and 15, a mold 500 is illustrated which is a modification of mold 400 described above with reference to Figures 8-13. In Figures 14 and 15, reference numerals with the same last two digits as those shown in Figures 8-13 are intended to indicate equal parts. Thus, for example, the mold 500 comprises a lid 505 and bowl 510. The lid 505 and bowl 510 are in a pivoting arrangement by means of a hinge 507.
    [065] As shown, a modification in mold 500 compared to mold 400 is the provision of two insertion elements 515a, 515b in mold 500 (cf. single insertion element 415 in mold 400). The inserts may have the same textured surface 520a, 520b or the textured surfaces may be different.
    [066] For example, if the foam part 540 is large, it may be advisable to use multiple inserts 515a, 515b. In addition or alternatively, it is possible to use different texture patterns for the textured surfaces 520a, 520b to convey different comfort characteristics for the foam element 520.
    [067] While this invention has been described with reference to illustrative modalities and examples, the description is not intended to be construed in a limiting sense. Thus, various modifications of the illustrative modalities, as well as other modalities of the invention, will be apparent to persons skilled in the art with reference to this description. Therefore, it is considered that the attached claims will cover such modifications or modalities. In addition, all claims are incorporated herein by reference in the description of preferred embodiments.
    [068] All publications, patents, and patent applications referred to herein are incorporated by reference in their entirety to the same extent as if each individual publication, patent, or patent application were specifically indicated or individually to be incorporated by reference in their entirety.
    权利要求:
    Claims (8)
    [0001]
    1. Padded element (300) comprising a foam substrate (315) having a first inner surface (325) and a second inner surface (330) opposite to the first inner surface (325), the first inner surface (325) being interposed between an outer surface (305) of the foam substrate (315) and the second inner surface, where the first inner surface (325) is textured, the foam substrate (315) is molded from a foam part unitary, and in which there is a free space between both internal surfaces (325, 330); CHARACTERIZED because the second inner surface (330) is non-textured.
    [0002]
    2. Padded element (300) according to claim 1, CHARACTERIZED by the fact that the structure of the first internal surface (325) comprises a plurality of peaks (327) and a plurality of valleys (329).
    [0003]
    3. Padded element (300), according to claim 1 or 2, CHARACTERIZED by the fact that the internal surfaces (325, 330), in an unoccupied state, are not in contact.
    [0004]
    4. Padded element (300) according to claim 2 or 3, CHARACTERIZED by the fact that the plurality of peaks are comprised in a plurality of vertical projections.
    [0005]
    5. Padded element (300), according to any of claims 2 to 4, CHARACTERIZED by the fact that the peaks (327) comprise the same shape.
    [0006]
    6. Padded element (300), according to any of claims 2 to 5, CHARACTERIZED by the fact that the plurality of peaks (327) have the same dimensions.
    [0007]
    7. Padded element (300), according to any of claims 2 to 5, CHARACTERIZED by the fact that the plurality of peaks (327) comprise different shapes.
    [0008]
    8. Padded element (300), according to any of claims 2 to 7, CHARACTERIZED by the fact that the plurality of peaks (329) comprise different dimensions.
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    同族专利:
    公开号 | 公开日
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    WO2013006959A1|2013-01-17|
    US20150028650A1|2015-01-29|
    RU2014102480A|2015-08-20|
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    CN103842284A|2014-06-04|
    MX2014000583A|2014-10-24|
    EP2731907A1|2014-05-21|
    EP3473591A1|2019-04-24|
    JP2018075366A|2018-05-17|
    EP2731907B1|2018-11-21|
    CA2841871A1|2013-01-17|
    BR112014000464A2|2017-02-21|
    KR20210082537A|2021-07-05|
    PL2731907T3|2019-06-28|
    JP6672238B2|2020-03-25|
    ES2711645T3|2019-05-06|
    CN103842284B|2016-10-12|
    EP2731907A4|2015-03-11|
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    法律状态:
    2018-03-27| B15K| Others concerning applications: alteration of classification|Ipc: B60N 2/70 (2006.01), A47C 7/18 (2006.01), A47C 27/ |
    2018-12-11| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-12-10| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-12-01| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-02-02| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 16/07/2012, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US201161457943P| true| 2011-07-14|2011-07-14|
    US61/457,943|2011-07-14|
    PCT/CA2012/000668|WO2013006959A1|2011-07-14|2012-07-16|Foam seat element, and process and mold for producing same|
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