Manufacturing method of lightweight saddle

Abstract

The present invention discloses a method for manufacturing a lightweight saddle. The manufacturing method successively includes the following steps: 1) Place the surface layer on the lower mold, and adsorb the surface layer in the cavity of the lower mold by means of vacuum adsorption; 2) Inject foaming liquid raw material into the cavity, attach a layer of shaping cloth to the upper mold, and then close the upper mold on the lower mold; 3) Heat the molding die to form an elastomer, and the surface layer is combined with the top and side peripheries of the elastomer, and the shaping cloth is shaped into a hard shell and combined with the bottom of the elastomer, and the whole is formed into a semi-finished saddle soft body; 4) Take out the semi-finished saddle soft body, trim off the redundant parts to form a semi-finished saddle soft body; 5) Fix the semi-finished saddle soft body and the bottom shell together to form a complete saddle. The present invention separately prefabricates the semi-finished saddle soft body first, and then forms the whole saddle by bonding the semi-finished saddle soft body and the bottom shell. The process is less, the production speed is fast, and the delicacy of the whole saddle is improved.

Description

Technical Field

[0001] The present invention belongs to the field of saddle production, and particularly relates to a method for manufacturing a lightweight saddle. Background Art

[0002] With the improvement of people's living standards and the enrichment of material life, the incidence of diseases caused by obesity is increasing in the population. Therefore, people are paying more and more attention to cycling sports that can not only meet the commuting requirements but also exercise the body. Different types of bicycles have become objects that people compete to buy, and the production capacity requirements for bicycles are getting higher and higher. Moreover, the aesthetics of the vehicle and the comfort of the saddle have also become key factors for people to choose and continue to use bicycles.

[0003] Generally, the main body of a bicycle seat cushion mainly includes a surface layer formed on the outer surface to form a wrapping, an elastic body disposed in the middle, and a rigid bottom shell disposed at the bottom. The traditional way of setting the surface layer is that after the elastic body and the bottom shell are combined, the surface layer is manually covered on the top of the elastic body, and the surface layer is tightened to fit on the elastic body. Then, the periphery of the surface layer is folded back under the bottom shell, and the periphery of the surface layer is fixed to the bottom shell by using glue or a staple gun. However, this method of setting the surface layer is not only quite time-consuming, but also easily causes the surface layer to be skewed or not to fit on the elastic body due to uneven tension of the surface layer. Especially for the surface layer made of synthetic plastic leather, its elasticity is small and it is more likely to cause the above problems. In addition, for a seat cushion body with a more complex shape, such as a seat cushion body with a perforation in the center, it is more difficult to set the surface layer in the above-mentioned manual way.

[0004] Chinese Patent with the application number 201510239425.2 provides a method for manufacturing a bicycle seat cushion body. Specifically: a) adsorbing a surface layer into a cavity of a forming mold by vacuum suction, so that the surface layer has a main area attached to an inner wall of the cavity and a peripheral area located around the main area; b) heating and forming a base material into an elastic body in the cavity of the forming mold, so that the main area of the surface layer is fittingly combined with the elastic body, and a bottom shell is combined with the elastic body; and c) folding back and fixing the peripheral area of the surface layer to a bottom of the bottom shell. Although this production method can avoid the problems of uneven force on the surface layer and the surface layer not fitting on the elastic body, and can also avoid the problem of uneven edges of the seat cushion body, but because it is necessary to fold back and fix the peripheral area of the surface layer to a bottom of the bottom shell, on the one hand, it still requires a lot of manual work for flanging and fixing with a staple gun or glue. On the other hand, because of the flanging, it will inevitably cause wrinkles at the edges, resulting in an unrefined appearance. Moreover, in order to protect the surface layer from direct friction with the ground and damage when the bicycle falls, it is also necessary to additionally fix an anti-abrasion protection frame on the rigid bottom shell after completing the folding and edge fixing, making the overall manufacturing process a bit complicated and the cost relatively high.

[0005] Therefore, in view of the fact that there are still many steps in the existing vehicle seat production that need to be completed manually, the production efficiency is low, and the precision is not enough, which makes it impossible to design the vehicle seat into a delicate shape and the production cost is high, people hope to find a better vehicle seat production method. Summary of the invention

[0006] The purpose of the invention is to provide a method for manufacturing a lightweight saddle with strong adaptability, fast production speed, high molding accuracy, low production cost and high overall strength.

[0007] The present invention is achieved through the following technical solutions:

[0008] A method for manufacturing a lightweight saddle, the saddle comprising a surface layer arranged on the outer surface to form a wrap, an elastic body arranged in the middle, and a hard bottom shell arranged at the bottom, the manufacturing method sequentially comprising the following steps:

[0009] 1) A molding die is mounted on a production line die frame, wherein the molding die comprises an upper die, a lower die and a skin pressing frame, wherein the upper die has a bottom surface and a die table protruding from the bottom surface, wherein the inner contour of the skin pressing frame matches the outer contour of the die table, and the lower die has a top surface and a mold cavity, wherein the mold cavity is recessed from the top surface; when the molding die is opened, a leather surface is placed on the lower die as a surface layer, and then the skin pressing frame is pressed against the top surface of the lower die through the surface layer, and then the surface layer is adsorbed into the mold cavity by vacuum adsorption, so that the surface layer has a main area attached to the inner wall of the mold cavity, and a peripheral area between the skin pressing frame and the top surface of the lower die;

[0010] 2) injecting a saddle inner elastic body forming foaming liquid raw material into the mold cavity, and attaching a layer of shaping cloth with shaping effect to the upper mold, and then closing the upper mold on the lower mold covered with a leather pressing frame;

[0011] 3) The forming mold is heated to allow the foaming liquid raw material to be foamed and formed into an elastic body, the main area of ​​the surface layer is combined with the top and side periphery of the elastic body, and the part of the shaping cloth that contacts the bottom of the elastic body is formed into a hard shell combined with the bottom of the elastic body, and the whole is formed into a saddle semi-finished soft body;

[0012] 4) Open the upper die, loosen the leather pressing frame, take out the semi-finished saddle soft body, trim off the excess part, and form a semi-finished saddle soft body;

[0013] 5) The semi-finished saddle soft body and the bottom shell are bonded and fixed together to form a complete saddle.

[0014] Preferably, in step 5), the specific steps of bonding and fixing the semi-finished saddle soft body and the bottom shell are as follows: Apply glue to both the semi-finished saddle soft body and the bottom shell, then manually position and pre-bond the semi-finished saddle soft body with the bottom shell, and finally fix and bond them through vacuum, achieving the effect of completely bonding the semi-finished saddle soft body and the bottom shell.

[0015] Preferably, a protective edge is integrally formed on the edge of the bottom shell to prevent the surface layer from directly contacting the ground when the vehicle topples over, thereby protecting the surface layer.

[0016] Preferably, the glue is a water-based glue.

[0017] Preferably, the shaping cloth is non-woven fabric, felt cloth, knitted cloth, etc. with a plastic effect.

[0018] Preferably, the surface structure of the mold table on the upper mold is adapted to the upper surface structure of the saddle bottom shell, so that the bottom structure of the semi-finished saddle soft body produced can perfectly fit the upper surface of the bottom shell.

[0019] Preferably, the lower mold includes a lower mold lower forming component and a lower mold upper forming component that cooperate with each other. A central mold cavity adapted to the shape of the saddle top is formed on the upper surface of the lower mold lower forming component; corresponding to the central mold cavity on the lower mold lower forming component, the lower mold upper forming component is hollowed out and formed with a side mold cavity that can form the shape of the saddle side periphery at the corresponding position. The inner contour of the side mold cavity coincides with the outer contour shape of the mold table on the upper mold. The central mold cavity and the side mold cavity together form a mold cavity that can be adapted to form the saddle surface structure.

[0020] More preferably, a lower template is further provided below the lower mold lower forming component. A negative pressure cavity is formed between the lower mold lower forming component and the lower template, and a sealing ring is buried at the negative pressure cavity joint. The negative pressure cavity is also connected to an air extraction device to produce a vacuum adsorption effect.

[0021] Further, the lower mold lower forming component and the lower template are fixed by screws.

[0022] More preferably, the lower mold upper forming component and the lower mold lower forming component are fixed together by a clamping method, and a sealing ring is provided at the clamping position.

[0023] Preferably, a plurality of locking seats are provided on both the upper mold and the lower mold. High-strength positioning pins are provided inside the locking seats, and locking bolts pass through the positioning pins to fix the upper mold and the lower mold to the mold rack respectively.

[0024] Preferably, a hinge is provided between the dough pressing frame and the lower mold at the rear edge, and a cylinder pushing device is further provided on the side surface. The dough pressing frame is turned relative to the lower mold through the hinge and the cylinder pushing device, and a locking device is further provided between the dough pressing frame and the lower mold.

[0025] The beneficial effects of the present invention are as follows:

[0026] The manufacturing method of the lightweight saddle of the present invention has a simple and ingenious process. First, the saddle semi-finished product software is prefabricated separately, and then the saddle semi-finished product software is bonded to the bottom shell to form the whole saddle. The production process is less, the production speed is fast, the amount of manual labor used is greatly reduced compared with the traditional process, the degree of automation is improved, and the delicacy of the whole saddle is improved. In particular, it has the following advantages:

[0027] 1. In the present invention, a layer of shaping cloth is attached to the upper mold instead of directly using a hard bottom shell. When the molding die is heated, it forms a hard shell layer with a certain binding force in the form of a pair of elastic bodies, so that the shape of the prefabricated saddle semi-finished product software can be kept precise, making it possible to prefabricate the saddle semi-finished product software.

[0028] 2. The method of prefabricating the saddle semi-finished product software first makes the edge interference-free after molding, and it is very convenient to trim the excess edging. Fast and fine trimming can be achieved, that is, even without edging, a beautiful effect can be achieved.

[0029] 3. The present invention does not require flanging and fixing the flanging, saving the edging and edging fixing processes, greatly saving labor, reducing the production difficulty, improving the production efficiency, and the surface layer edge will also be very smooth, without any wrinkles due to flanging and nailing, etc., and the aesthetic degree is greatly improved.

[0030] 4. The plastic cloth is heated to become a hard shell. While ensuring the precise molding of the saddle semi-finished product software without the presence of a hard bottom shell, the hard shell itself provides an additional support for the saddle. Then it is connected to the hard bottom shell through an adhesive layer, further improving the overall strength of the saddle, making it more durable and very lightweight.

[0031] 5. In order to prevent the surface layer from being damaged by direct friction with the ground when the bicycle falls, in the traditional production process, usually after the edging is completed, an anti-friction protection ring that can surround the edge of the bottom shell is fixed on the bottom shell. However, because there is no edging on the saddle in the present invention, there is no need to fix another anti-friction protection structure for protecting the surface layer on the bottom shell. This anti-friction protection structure can be directly integrally formed on the bottom plate, not only saving the subsequent process, but also saving the production cost of parts, making the saddle further lightweight.

[0032] 6. When the lower mold is of a combined structure, when it is necessary to produce saddles with different edge forms, it is only necessary to replace the forming components on the lower mold with components that match the edge structure required by the customer to quickly achieve production, without the need to additionally configure a complete set of molds. The production adaptability is strong and the flexibility is good. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] For ease of description, the present invention will be described in detail by the following specific embodiments and accompanying drawings.

[0034] Figure 1 Schematic perspective view of the lightweight saddle manufactured by the method of the present invention;

[0035] Figure 2 For Figure 1 bottom view of

[0036] Figure 3 For Figure 2 A-A sectional view of

[0037] Figure 4 Schematic perspective view of the mold used in the method of the present invention when opened;

[0038] Figure 5 For Figure 4 side view of

[0039] Figure 6 Schematic perspective view of the mold used in the method of the present invention when closed;

[0040] Figure 7 For Figure 6 side view of

[0041] Figure 8 For Figure 7 B-B sectional view of

[0042] Figure 9 Schematic diagram of surface layer forming in this method;

[0043] Figure 10 Schematic diagram of the structure of the shaping cloth;

[0044] Figure 11 Schematic diagram of the forming of the semi-finished saddle software in the mold in the present invention;

[0045] Figure 12 Schematic diagram of the structure of the untrimmed semi-finished saddle software and the bottom shell before combination in the present invention;

[0046] Figure 13 Schematic diagram of the structure of the semi-finished saddle software and the bottom shell after combination in the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0047] Such asFigures 1-13 As shown, a method for manufacturing a lightweight saddle, the saddle comprises a surface layer 1 arranged on the outer surface to form a wrap, an elastic body 2 arranged in the middle and a hard bottom shell 3 arranged at the bottom, and the manufacturing method comprises the following steps in sequence:

[0048] 1) A molding mold is mounted on a mold frame of a production line, wherein the molding mold comprises an upper mold 10, a lower mold 20 and a leather pressing frame 30, wherein the upper mold 10 has a bottom surface and a mold platform 11 protruding from the bottom surface, wherein the inner contour of the leather pressing frame 30 matches the outer contour of the mold platform 11, and the lower mold 20 has a top surface 21 and a mold cavity 22, wherein the mold cavity 22 is recessed from the top surface; when the molding mold is opened, a leather surface is placed on the lower mold 20 as a surface layer 1, and then the leather pressing frame 30 is pressed against the top surface of the lower mold 20 through the surface layer 1, and then the surface layer 1 is adsorbed into the mold cavity 22 by vacuum adsorption, so that the surface layer 1 has a main area attached to the inner wall of the mold cavity 22, and a peripheral area between the leather pressing frame 30 and the top surface of the lower mold 20;

[0049] 2) Injecting the saddle inner elastic body 2 into the mold cavity 22 to form a foaming liquid raw material, and attaching a layer of shaping cloth 4 with a shaping effect to the upper mold 10, and then closing the upper mold 10 on the lower mold 20 covered with a skin pressing frame 30;

[0050] 3) The forming mold is heated to allow the foaming liquid raw material to be foamed and formed into an elastic body 2, the main area of ​​the surface layer 1 is combined with the top and side periphery of the elastic body 2, and the part of the shaping cloth 4 that contacts the bottom of the elastic body 2 is formed into a hard shell and combined with the bottom of the elastic body 2, so that the whole is formed into a semi-finished soft saddle;

[0051] 4) Open the upper mold 10, loosen the leather pressing frame 30, take out the semi-finished saddle soft body, trim off the excess part, and form a semi-finished saddle soft body 40;

[0052] 5) The semi-finished saddle soft body 40 and the bottom shell 3 are bonded and fixed together to form a complete saddle.

[0053] In step 5), the specific steps of bonding and fixing the semi-finished saddle soft body 40 and the bottom shell 3 are: applying glue on the semi-finished saddle soft body 40 and the bottom shell 3, then manually positioning and pre-bonding the semi-finished saddle soft body and the bottom shell, and finally bonding by vacuum fixing, so as to achieve a thorough bonding effect of the semi-finished saddle soft body and the bottom shell. The vacuum fixing bonding process is implemented according to the existing prior art process.

[0054] The bottom shell 3 is integrally formed with a protective edge 31 to prevent the surface from directly contacting the ground when the vehicle falls over, thereby protecting the surface.

[0055] The glue is water-based glue.

[0056] The shaping cloth 4 is non-woven fabric, felt cloth, knitted cloth, etc. with plastic effect.

[0057] The surface structure of the mold table 11 on the upper mold 10 is adapted to the upper surface structure of the saddle bottom shell 3, so that the bottom structure of the semi-finished saddle soft body 40 produced can be perfectly matched with the upper surface of the bottom shell 3.

[0058] The lower mold 20 includes a lower mold lower forming component 23 and a lower mold upper forming component 24 which cooperate with each other. A central mold cavity adapted to the shape of the saddle top is formed on the upper surface of the lower mold lower forming component 23; corresponding to the central mold cavity on the lower mold lower forming component 23, the lower mold upper forming component 24 is hollowed out and formed at a corresponding position with a side mold cavity capable of forming the shape of the saddle side periphery. The inner contour of the side mold cavity coincides with the outer contour shape of the mold table on the upper mold. The central mold cavity and the side mold cavity together form a mold cavity 22 capable of adapting to form the saddle face structure.

[0059] A lower template 25 is further provided below the lower mold lower forming component 23. A negative pressure cavity 26 is formed between the lower mold lower forming component 23 and the lower template 25, and a sealing ring is buried at the negative pressure cavity joint. The negative pressure cavity is also connected to an air extraction device to produce a vacuum adsorption effect.

[0060] The lower mold lower forming component 23 and the lower template 25 are fixed by screws.

[0061] The lower mold upper forming component 23 and the lower mold lower forming component 24 are fixed together by a clamping method, and a sealing ring is provided at the clamping position.

[0062] A plurality of locking seats are provided on both the upper mold 10 and the lower mold 20. High-strength positioning pins are provided inside the locking seats, and locking bolts pass through the positioning pins to fix the upper mold and the lower mold to the mold rack respectively.

[0063] A hinge 27 is provided on the rear edge between the leather pressing frame 30 and the lower mold 20, and a cylinder pushing device 28 is also provided on the side. The leather pressing frame 30 is flipped relative to the lower mold 20 through the hinge 27 and the cylinder pushing device 28. A locking device (not shown) is also provided between the leather pressing frame 30 and the lower mold 20.

[0064] The lightweight saddle manufacturing method of the present invention has a simple and ingenious process. First, the saddle semi-finished soft body is prefabricated separately, and then the saddle semi-finished soft body is bonded to the bottom shell to form the whole saddle. The production process is less, the production speed is fast, the labor usage is greatly reduced compared with the traditional process, the automation degree is improved, and the delicacy of the whole saddle is improved. In particular, it has the following advantages:

[0065] 1. In the present invention, instead of directly mounting a rigid bottom shell on the upper mold, a layer of shaping cloth is attached to the upper mold. When the molding die is heated, it forms a hard shell layer with a certain binding force in the form of a pair of elastic bodies, enabling the precise maintenance of the shape of the prefabricated semi-finished saddle soft body, thus making it possible to prefabricate the semi-finished saddle soft body.

[0066] 2. By prefabricating the semi-finished saddle soft body first, there is no interference from the rigid bottom shell at the edge after molding, making it very convenient to trim the excess hemming. Quick and precise trimming can be achieved, that is, even without hemming, an aesthetic effect is achieved.

[0067] 3. The present invention does not require hemming and fixing the hemming, saving the hemming and hemming fixing processes, greatly saving labor, reducing the production difficulty, improving the production efficiency, and the surface edge will also be very smooth, without any wrinkles due to hemming and nailing, etc., greatly enhancing the aesthetic degree.

[0068] 4. The plastic cloth is heated to become a hard shell. While ensuring the precise molding of the semi-finished saddle soft body in the absence of a rigid bottom shell, the hard shell itself provides an additional support for the saddle. Then, it is connected to the rigid bottom shell through an adhesive layer, further improving the overall strength of the saddle, making it more durable and very lightweight.

[0069] 5. To prevent the surface layer from being damaged by direct friction with the ground when the bicycle falls over, in the traditional production process, usually after hemming is completed, an anti-friction protection ring that can surround the edge of the bottom shell is fixed on the bottom shell. However, because there is no hemming on the saddle in the present invention, there is no need to separately fix an anti-friction protection structure for protecting the surface skin on the bottom shell. This anti-friction protection structure can be directly integrally formed on the bottom plate, not only saving the subsequent processes but also saving the production cost of parts, making the saddle further lightweight.

[0070] 6. When the lower mold is of a combined structure, when producing saddles with different edge shapes, only need to replace the molding components on the lower mold with components matching the edge structure required by the customer to quickly achieve production, without the need to additionally configure a whole set of molds, with strong production adaptability and good flexibility.

[0071] The above is only the specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any change or replacement that can be thought of without creative work should be covered within the protection scope of the present invention. Therefore, the protection scope of the present invention should be subject to the protection scope defined by the claims.

Claims

1. A method for manufacturing a lightweight saddle, the saddle comprising a surface layer provided on the outer surface to form a wrap, an elastomer provided in the middle, and a rigid bottom shell provided at the bottom, characterized in that, The manufacturing method comprises the following steps in sequence: 1) A molding die is mounted on a production line die frame, wherein the molding die comprises an upper die, a lower die and a skin pressing frame, wherein the upper die has a bottom surface and a die table protruding from the bottom surface, wherein the inner contour of the skin pressing frame matches the outer contour of the die table, and the lower die has a top surface and a mold cavity, wherein the mold cavity is recessed from the top surface; when the molding die is opened, a leather surface is placed on the lower die as a surface layer, and then the skin pressing frame is pressed against the top surface of the lower die through the surface layer, and then the surface layer is adsorbed into the mold cavity by vacuum adsorption, so that the surface layer has a main area attached to the inner wall of the mold cavity, and a peripheral area between the skin pressing frame and the top surface of the lower die; 2) injecting a saddle inner elastic body forming foaming liquid raw material into the mold cavity, and attaching a layer of shaping cloth with shaping effect to the upper mold, and then closing the upper mold on the lower mold covered with a leather pressing frame; 3) The forming mold is heated to allow the foaming liquid raw material to be foamed and formed into an elastic body, the main area of ​​the surface layer is combined with the top and side periphery of the elastic body, and the part of the shaping cloth that contacts the bottom of the elastic body is formed into a hard shell combined with the bottom of the elastic body, and the whole is formed into a saddle semi-finished soft body; 4) Open the upper die, loosen the leather pressing frame, take out the semi-finished saddle soft body, trim off the excess part, and form a semi-finished saddle soft body; 5) Bonding and fixing the semi-finished saddle soft body and the bottom shell together to form a complete saddle; The shaping cloth includes non-woven fabrics, felt fabrics, and knitted fabrics with plastic effects; the surface structure of the mold base on the upper mold is adapted to the upper surface structure of the saddle bottom shell, so that the bottom structure of the semi-finished saddle software can perfectly match the upper surface of the bottom shell; the lower mold includes a lower mold lower molding component and a lower mold upper molding component that cooperate with each other, and a central mold cavity adapted to the top shape of the saddle is formed on the upper surface of the lower mold lower molding component; corresponding to the central mold cavity on the lower mold lower molding component, the lower mold upper molding component is hollowed out at the corresponding position to form a side mold cavity that can form the side peripheral shape of the saddle, and the inner contour of the side mold cavity is consistent with the outer contour of the mold base on the upper mold, and the central mold cavity and the side mold cavity cooperate together to form a mold cavity that can adapt to the molding of the saddle surface structure of the saddle.

2. The manufacturing method of the lightweight saddle according to claim 1, characterized in that, In step 5), the specific steps of bonding and fixing the semi-finished saddle soft body and the bottom shell are: applying glue on the semi-finished saddle soft body and the bottom shell, then manually positioning the semi-finished saddle soft body and the bottom shell for pre-bonding, and finally bonding them by vacuum fixing, so as to achieve a thorough bonding effect between the semi-finished saddle soft body and the bottom shell.

3. The lightweight saddle manufacturing method according to claim 1, characterized in that, The bottom shell edge is integrally formed with a protective edge to prevent the surface layer from directly contacting the ground when the vehicle falls over, thereby protecting the surface layer.

4. The method for manufacturing a lightweight saddle according to claim 1, characterized in that, A lower mold plate is also provided below the lower mold lower molding assembly, a negative pressure chamber is formed between the lower mold lower molding assembly and the lower mold plate, and a sealing ring is buried at the junction of the negative pressure chamber. The negative pressure chamber is also connected to a vacuum device to produce a vacuum adsorption effect.

5. The manufacturing method of the lightweight saddle according to claim 1, characterized in that The upper forming component on the lower die and the lower forming component under the lower die are fixed together by a clamping method, and a sealing ring is provided at the clamping position.

6. The manufacturing method of the lightweight saddle according to claim 1, characterized in that, A number of locking seats are provided on both the upper die and the lower die. Inside each locking seat, a high-strength positioning pin is provided, and a locking bolt passes through the positioning pin to fix the upper die and the lower die to the mold frame respectively.

7. The manufacturing method of the lightweight saddle according to claim 1, characterized in that A hinge is provided on the rear edge between the leather pressing frame and the lower die, and a cylinder pushing device is also provided on the side. The leather pressing frame can be flipped relative to the lower die through the hinge and the cylinder pushing device, and a locking device is also provided between the leather pressing frame and the lower die.

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