Injection molded vibrator, method of molding and method of mounting

Abstract

The application discloses an integrally-injected vibrator, which comprises a shell and a vibration component, wherein the shell is formed by an upper cover unit and a lower cover unit; the upper cover unit is formed by an upper cover shell and a plurality of elastic strips; the lower cover unit is formed by a lower cover shell and a bottom plate; and the elastic strips are integrally injected on the upper cover shell. The vibrator has a long service life and low cost. The application also provides a corresponding forming method and mounting method of the integrally-injected vibrator.

Description

TECHNICAL FIELD

[0001] The present application relates to a vibration generating device, in particular to a vibrator suitable for leisure massage equipment such as electric beds, electric sofas, etc. BACKGROUND

[0002] The existing vibrator is complex to assemble and consumes labor. The existing vibrator has a complex process and is difficult to manufacture. The existing vibrator has high precision requirements, otherwise it is easy to produce vibration noise. The existing vibrator has many parts and is complex.

[0003] For example, the 202120694059.0 Chinese utility model patent disclosed on November 23, 2021 discloses a vibrator, which includes three components: a vibration motor, a mounting base, and a pressure plate. During installation, the vibration motor needs to be connected with the mounting base, and the pressure plate at the bottom is connected with the mounting base. Then, the vibrator is connected with the bed plate through screws and other parts. During the entire process, the mounting base that provides amplitude and the vibration motor are two parts that need to be separated during manufacturing, resulting in a large amount of labor loss. The design size of the mounting base itself is large, and there is a long installation fixing edge, which wastes a lot of materials and has no advantage in cost.

[0004] For another example, the 201721788296.3 Chinese utility model patent disclosed on March 22, 2019 discloses a vibrator, which includes four parts: an upper cover, a rubber sheet, a vibration motor, and a lower cover. This vibrator needs to be assembled with the rubber sheet during installation. Since there is no screw design, the assembly is usually through the elastic force of the rubber sheet itself, so that the parts of the vibration motor pass through the middle hole of the rubber sheet to be connected. During this process, it is usually an interference fit, which is difficult to assemble. Then, the rubber sheet is fixed by using the upper cover plate and the lower cover plate, and finally installed on the bed plate by using screws and other parts. Therefore, during assembly, the rubber sheet is difficult to install. There are many parts during installation, and the installation time is long. The rubber sheet is too large in size and lacks elasticity, which can easily cause the bed plate to resonate, and the material cost is high.

[0005] For another example, the 201820702954.0 Chinese utility model patent disclosed on September 3, 2019 also discloses a vibrator, which is divided into four parts: a fixed frame, an elastic wrapping sheet, a vibration motor, and a vibration plate. During installation, the elastic wrapping sheet is first connected with the vibration motor (as above), which is difficult to install. Then, the vibration plate is connected with the vibration motor. Subsequently, the elastic wrapping sheet is connected with the fixed frame, and finally the vibration plate is connected with the bed plate by using screws. Therefore, during assembly, the rubber sheet is difficult to install. There are many parts during installation, and the installation time is long. The vibration motor and the fixed plate are connected by clamping, which is not a fixed connection. When vibrating, there may be a collision, which produces noise. SUMMARY

[0006] It is an object of the present application to at least overcome one of the deficiencies of the prior art shakers, to provide an improved shaker structure.

[0007] To this end, some embodiments of the present application provide an integrally injection molded shaker, comprising a housing and a vibration assembly, wherein the housing is formed by an upper cover unit and a lower cover unit; wherein the upper cover unit is formed by an upper cover shell and a plurality of elastic strips, and the lower cover unit is formed by a lower cover shell and a bottom plate; the elastic strips are injection molded on the upper cover shell.

[0008] In some embodiments, the upper cover unit comprises first shell connecting blocks for connecting with the lower cover by screws, including two first middle connecting blocks for fixing the shell and / or two first end connecting blocks for further closing the two shells; the lower cover unit comprises second shell connecting blocks corresponding to the structure of the first shell connecting blocks of the upper cover unit, including two second middle connecting blocks for fixing the shell and two second end connecting blocks.

[0009] In some embodiments, the upper cover unit comprises a plurality of polygonal limiting blocks at the axial ends of a first motor mounting sub-region inside the upper cover unit; the first motor mounting sub-region is provided with a circumferentially arranged first annular rib along the inner surface of the upper cover shell; the lower cover unit comprises a second motor mounting sub-region for accommodating the motor, and the axial ends of the second motor mounting sub-region are provided with polygonal limiting blocks for limiting the axial movement of the motor; the lower cover unit is provided with a circumferentially arranged second annular rib along the inner surface of the lower cover shell at the second motor mounting sub-region to limit the radial movement of the motor; after the upper cover shell and the lower cover shell are buckled, the first motor mounting sub-region and the second motor mounting sub-region inside form a complete motor mounting region conforming to the outer contour of the motor.

[0010] In some embodiments, the lower cover unit comprises a lower cover shell for accommodating the vibration assembly and a lower cover bottom plate extending transversely from the bottom surface of the lower cover shell for increasing the contact area with the bed surface.

[0011] In some embodiments, the lower cover bottom plate of the lower cover unit is provided with a large-area reinforcing rib to improve the stability of the shaker.

[0012] In some embodiments, the upper cover shell and the lower cover unit are obtained by injection molding including polystyrene (PS), polyoxymethylene (POM), polyolefin (PP), polycarbonate (PC), and nylon (PA).

[0013] In some embodiments, the elastic body is fixed to the upper cover shell, including a fixed part for being directly or indirectly fixed to the bed plate, an upper cover positioning part of the upper cover unit, and an elastic section extending between the cylindrical fixed part and the upper cover positioning part.

[0014] In some embodiments, a positioning channel is provided on the upper cover housing for the connection of the elastic strip; the upper cover positioning part is configured to include an outer upper cover positioning part located on the outside of the upper cover, an inner upper cover positioning part located on the inside of the upper cover, and an upper cover positioning connecting part connecting the outer upper cover positioning part and the inner upper cover positioning part through the positioning channel.

[0015] In some embodiments, the outer upper cover positioning part is substantially a quadrangular prism configuration with an end face conforming to the surface profile of the upper cover on the side engaging the upper cover, and the inner upper cover positioning part is a sheet structure; the upper cover positioning connecting part is a strip structure filling the entire groove, with its upper end face engaging the outer upper cover positioning part and its lower end face engaging the inner upper cover positioning part.

[0016] In some embodiments, the inner upper cover positioning part is substantially a trapezoidal body structure.

[0017] In some embodiments, for each elastic strip, the positioning channel is one, two or more grooves or holes through the upper cover housing.

[0018] In some embodiments, the positioning channel is two grooves, and the upper cover positioning connecting part is two, respectively engaging different positions of the outer upper cover positioning part and the inner upper cover positioning part.

[0019] In some embodiments, the upper cover housing has an upper cover positioning column, and the outer upper cover positioning part provides a corresponding matching hole so that the positioning column passes through the end of the outer upper cover positioning part 1 and engages the upper cover positioning part.

[0020] In some embodiments, the elastic segment includes multiple sub-segments with different configurations.

[0021] In some embodiments, the elastic segment is a first elastic sub-segment in an elongated cylindrical or prismatic configuration, and a second elastic sub-segment in a substantially cuboid configuration with a transverse dimension larger than that of the first elastic sub-segment, the transverse dimension of the second elastic sub-segment being substantially the same as that of the upper cover positioning part, and its thickness being smaller than that of the upper cover positioning part and smaller than that of the first elastic sub-segment.

[0022] In some embodiments, a third elastic sub-segment with gradually changing thickness or segmented thickness is provided between the second elastic sub-segment and the upper cover positioning part.

[0023] In some embodiments, the four elastic bodies are arranged in pairs of axesymmetrically on the upper cover shell, so that the resultant force of the first elastic force (i.e. pulling force) F1, the second elastic force F2, the third elastic force F3, and the fourth elastic force F4 generated by the four elastic bodies is balanced with the upward pressure P and the gravity G.

[0024] In some embodiments, the first extension line P1, the second extension line P2, the third extension line P3, and the fourth extension line P4 of the directions of the first elastic force F1, the second elastic force F2, the third elastic force F3, and the fourth elastic force F4 of the four elastic bodies intersect on the two central axes of the vibrator.

[0025] In some embodiments, the area of the region P surrounded by the first extension line, the second extension line, the third extension line, and the fourth extension line is greater than 10% of the cross-sectional area of the vibration motor.

[0026] In some embodiments, the elastic strips are made of one kind of material, which includes thermoplastic elastomer (TPE for short), plastic, thermoplastic rubber (TPR for short), silicone, rubber, etc.; or the elastic strips are made of more than one kind of material.

[0027] In some embodiments, the vibrator is directly fixed to the bed plate by screws.

[0028] In some embodiments, a mounting fixing plate is further included, and the vibrator is indirectly fixed to the bed plate via the mounting fixing plate.

[0029] In some embodiments, the mounting fixing plate has a substantially rectangular frame structure, including positioning portions located at the four corners of the rectangular frame structure, and four edge frame strips connecting the four positioning portions; wherein the positioning portions are provided with positioning grooves for the elastic strips of the vibrator, and each positioning groove is matched with the fixing portion of one elastic strip of the upper cover.

[0030] In some embodiments, there are downwardly protruding fixing frame positioning blocks on the four edge frame strips of the mounting fixing plate, which can quickly position the mounting fixing plate and the opening of the bed plate.

[0031] In some embodiments, reinforcing ribs are provided on the edge frame strips.

[0032] In some embodiments, the edge frame strips of the mounting fixing plate further include upwardly protruding and horizontally extending fixing plate line clamps.

[0033] In some embodiments, the vibration assembly is mounted inside the housing, the vibration assembly includes a motor for providing power; an eccentric block connected to a motor shaft of the motor for providing periodic eccentric force; and an elastic material formed into a gap-eliminating component attached to a metal shell of the motor to eliminate the gap between the motor and the upper cover shell and the lower cover shell.

[0034] In some embodiments of the present application, the elastic wrapping sheet in the original vibrator is cancelled and replaced by an elastic strip connected to the vibrator motor shell, which can reduce the assembly man-hours on the elastic strip.

[0035] In some embodiments of the present application, the original vibration plate is combined with the motor shell to reduce the assembly man-hours of the vibration plate and reduce the vibration between the vibration plate and the vibration motor.

[0036] In some embodiments of the present application, the end of the elastic strip enters the interior of the upper cover unit, thereby increasing the connection area with the upper cover shell, reducing the stress at the contact between the two, and thereby increasing the service life of the elastic strip and the service life of the vibrator.

[0037] Therefore, another object of the present application is to at least overcome one of the deficiencies of the forming method of the vibrator in the prior art, and to provide an improved forming method of the vibrator.

[0038] Therefore, some other embodiments of the present application provide a forming method of the above-mentioned integrally injection-molded vibrator, which includes forming the upper cover unit by using a secondary injection molding method; first injection molding the upper cover shell, and separately or in combination forming the positioning column and / or the positioning channel for contacting with the elastic body on the upper cover shell formed by the primary injection molding; and then injection molding the elastic material on the formed upper cover shell, including passing the molten material of the elastic body through the positioning channel of the upper cover shell to form the inner side upper cover positioning part on the inner side thereof, and forming the upper cover positioning connecting part connecting the outer side upper cover positioning part and the inner side upper cover positioning part in the positioning channel.

[0039] Some other embodiments of the present application also disclose a mounting method of the above-mentioned integrally injection-molded vibrator, which includes directly fixing the elastic body to the bed plate by the screw of the vibrator; or providing a mounting fixing plate for the vibrator, fixing the elastic body to the mounting fixing plate by the elastic strip, and indirectly fixing the vibrator to the bed plate by the mounting fixing plate.

[0040] In some embodiments, when the vibrator is directly mounted to the bed plate, grooves are positioned at the positions corresponding to the elastic body at the four corners of the vibration mounting hole of the bed plate, and the vibrator is mounted through the positioning grooves when the vibrator is mounted.

[0041] In some embodiments, the fabric on the bed plate is processed, the processing including: making an X-shaped cut at a corresponding position of the bottom fabric where the vibrator is to be installed; folding down the four cut fabric portions of the fabric, over the bed plate; fixing the bottom fabric at the bed surface bending line; fixing the longer cut fabric portion to the other fabric so as to conform to the surface of the bed plate; and assembling the vibrator by sensing the positioning groove covered by the fabric on the bed plate when installing the vibrator. BRIEF DESCRIPTION OF DRAWINGS

[0042] Figure 1 is a structural perspective view of a vibrator according to an embodiment of the present application.

[0043] Figure 2 is a structural top view of a vibrator according to an embodiment of the present application.

[0044] Figure 3 is a structural exploded view of a vibrator according to an embodiment of the present application.

[0045] Figure 4 is a structural perspective view of an upper cover unit of a vibrator according to an embodiment of the present application.

[0046] Figure 5 is a structural perspective view of an upper cover unit of a vibrator according to an embodiment of the present application.

[0047] Figure 6A is a structural perspective view of an upper cover housing of a vibrator according to an embodiment of the present application.

[0048] Figure 6B is a structural top view of an upper cover housing of a vibrator according to an embodiment of the present application.

[0049] Figure 6C is a structural bottom view of an upper cover housing of a vibrator according to an embodiment of the present application.

[0050] Figure 7A is a structural top view of an elastic strip of a vibrator according to an embodiment of the present application.

[0051] Figure 7B is a structural perspective view of an elastic strip of a vibrator according to an embodiment of the present application.

[0052] Figure 8A is a structural view of an upper cover housing of a vibrator according to an embodiment of the present application, combined with an elastic body.

[0053] Figure 8B is a structural view of an upper cover housing of a vibrator according to an embodiment of the present application, combined with an elastic body.

[0054] Figure 9A is a structural cross-sectional view of an upper cover case of a vibrator according to an embodiment of the present application and an elastic body and a structure viewed in a first direction after being combined.

[0055] Figure 9B is a structural cross-sectional view of an upper cover case of a vibrator according to an embodiment of the present application and an elastic body and a structure viewed in a second direction after being combined.

[0056] Figure 10 is a structural cross-sectional view of an upper cover case of a vibrator according to an embodiment of the present application and an elastic body and a structure viewed in a second direction after being combined.

[0057] Figure 11 is a structural cross-sectional view of an upper cover case of a vibrator according to an embodiment of the present application and an elastic body and a structure viewed in a second direction after being combined.

[0058] Figure 12A is a structural cross-sectional view of an upper cover case of a vibrator according to an embodiment of the present application and an elastic body and a structure viewed in a second direction after being combined.

[0059] Figure 12B is a structural cross-sectional view of an upper cover case of a vibrator according to an embodiment of the present application and an elastic body and a structure viewed in a second direction after being combined.

[0060] Figure 13A is a structural cross-sectional view of an upper cover case of a vibrator according to an embodiment of the present application and an elastic body and a structure viewed in a second direction after being combined.

[0061] Figure 13B is a structural cross-sectional view of an upper cover case of a vibrator according to an embodiment of the present application and an elastic body and a structure viewed in a second direction after being combined.

[0062] Figure 13C is a structural cross-sectional view of an upper cover case of a vibrator according to an embodiment of the present application and an elastic body and a structure viewed in a second direction after being combined.

[0063] Figure 13D is a structural cross-sectional view of an upper cover case of a vibrator according to an embodiment of the present application and an elastic body and a structure viewed in a second direction after being combined.

[0064] Figure 13E is a structural cross-sectional view of an upper cover case of a vibrator according to an embodiment of the present application and an elastic body and a structure viewed in a second direction after being combined.

[0065] Figure 13F is a structural cross-sectional view of an upper cover case of a vibrator according to an embodiment of the present application and an elastic body and a structure viewed in a second direction after being combined.

[0066] Figure 13G is a structural cross-sectional view of an upper cover case of a vibrator according to an embodiment of the present application and an elastic body and a structure viewed in a second direction after being combined. Figure 13F is a structural cross-sectional view of an upper cover case of a vibrator according to an embodiment of the present application and an elastic body and a structure viewed in a second direction after being combined.

[0067] Figure 13His a structure diagram of a vibration device mounted on a bed board according to another embodiment of the present application.

[0068] Figure 14A is a structure diagram of a vibration device mounted on a bed board according to another embodiment of the present application.

[0069] Figure 14B is a structure diagram of a vibration device mounted on a bed board according to another embodiment of the present application.

[0070] Figure 15A is a structure diagram of a vibration device mounted on a bed board according to another embodiment of the present application.

[0071] Figure 15B is a structure diagram of a vibration device mounted on a bed board according to another embodiment of the present application.

[0072] Figure 15C is a structure diagram of a vibration device mounted on a bed board according to another embodiment of the present application.

[0073] Figure 16 is a structure diagram of a vibration device mounted on a bed board according to another embodiment of the present application.

[0074] Figure 17 is a structure diagram of a vibration device mounted on a bed board according to another embodiment of the present application. DETAILED DESCRIPTION

[0075] The features of the present application will be further described in the following embodiments.

[0076] The specific structural and functional details disclosed herein are merely representative for purposes of describing the exemplary embodiments of the present application. The present application, however, can be embodied in many alternatives, and should not be construed as limited to the embodiments set forth herein.

[0077] It should be understood that, although the terms "first", "second", etc. can be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0078] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments. Unless the context clearly indicates otherwise, the singular forms “a” and “an” as used herein are also intended to include the plural. It should also be understood that the terms “comprising” and / or “including” as used herein specify the presence of the stated features, integers, steps, operations, units, and / or components, without excluding the presence or addition of one or more other features, integers, steps, operations, units, components, and / or combinations thereof.

[0079] It should also be mentioned that in some alternative implementations, the functions / actions mentioned may occur in a different order than those shown in the figures. For example, depending on the functions / actions involved, the two figures shown successively may actually be executed substantially simultaneously or sometimes in reverse order.

[0080] like Figure 1 , Figure 2 , Figure 3 As shown, a vibrator 100 according to an embodiment of this application includes a housing 10 and a vibration assembly 20. The housing 10 is formed by an upper cover unit 11 and a lower cover unit 12. The upper cover unit 11 is formed by joining an upper cover shell 111 and a plurality of elastic strips 112, and the lower cover unit 12 is formed by a lower cover shell 121 and a base plate 122. The vibration assembly 20 may, for example, consist of a motor 21, an eccentric block 22, and a backlash-free component 23 formed of an elastic material.

[0081] like Figure 4 , Figure 5 As shown, the upper cover unit 11 includes a first housing connecting block 114 for connection to the lower cover unit 12 via screws. It may include two first middle connecting blocks 1141 for fixing the housing, and two first end connecting blocks 1142 to further close the two housings, preventing noise from the two housings colliding when the vibrator is operating. In other embodiments, it may only include the first middle connecting blocks or only the first end connecting blocks to fix the two housings.

[0082] like Figure 5 As shown, to limit the axial movement of the motor 21 inside the housing, polygonal limiting blocks 113 can be provided at both ends of the axial direction of the first motor mounting sub-region inside the upper cover unit 11. To limit the radial movement of the motor 21, a first annular rib 115 arranged circumferentially can also be provided along the inner surface of the upper cover in the first motor mounting sub-region, for example, as shown in the figure. Figure 5 The three first annular reinforcing bars are shown. For example... Figure 5As shown, the upper cover unit 11 can further include a motor outlet 116 for passing the power cable. In some embodiments, the upper cover unit 11 can further include a first snap groove 117 conforming to the profile of the upper cover housing, the annular snap groove 117 being configured to snap with the corresponding structure of the lower cover unit 12 to improve the tightness of the housing 10.

[0083] In some embodiments, as shown in FIG. 6A, the upper cover housing 111 can be provided with a positioning channel 119 for the connection of the elastic strip 112. For each elastic strip, the positioning channel 119 can be one, two or more, for example, as shown in FIG. 6C. Figure 6A 、 6B As shown in FIG. 6C, the positioning channel can be two grooves through the upper cover housing, which can be arranged at an angle. For the sake of convenience, only the positioning channel corresponding to one elastic strip is labeled in the figure, and the positioning channels of the other elastic strips are determined according to the arrangement of the elastic strips. For example, for the four elastic strips arranged symmetrically about the axis shown in the figure, the corresponding positioning channels are also arranged symmetrically about the axis to ensure the balance of the force. Figure 6A 、 6B As shown in FIG. 6C, the positioning channel can be two grooves through the upper cover housing, which can be arranged at an angle. For the sake of convenience, only the positioning channel corresponding to one elastic strip is labeled in the figure, and the positioning channels of the other elastic strips are determined according to the arrangement of the elastic strips. For example, for the four elastic strips arranged symmetrically about the axis shown in the figure, the corresponding positioning channels are also arranged symmetrically about the axis to ensure the balance of the force.

[0084] In some embodiments, further or alternatively, positioning posts 118 can be arranged on the surface of the upper cover housing 111 at the region where the elastic strips are joined. The positioning posts 118 can be at least one, two or more. Similar to the positioning channel, the positioning posts 118 are arranged according to the arrangement of the corresponding elastic strips, for example, symmetrically about the axis.

[0085] Correspondingly, as shown in FIG. 6B, the lower cover unit 12 includes a lower cover housing 121 for accommodating the vibration assembly 20 and a lower cover bottom plate 122 extending transversely from the bottom surface of the lower cover housing 121 for increasing the contact area with the bed surface. The lower cover unit 12 includes a second housing connecting block 124 corresponding to the structure of the first housing connecting block 114 of the upper cover unit, so as to be connected with the upper cover unit 11 by screws, for example, which can include two second middle connecting blocks 1241 for fixing the housing and two second end housing connecting blocks 1242 for closing the housing to prevent the upper cover housing 111 and the lower cover housing 121 from colliding and making noise when the vibrator is working. Figure 12A 12B Correspondingly, as shown in FIG. 6B, the lower cover unit 12 includes a lower cover housing 121 for accommodating the vibration assembly 20 and a lower cover bottom plate 122 extending transversely from the bottom surface of the lower cover housing 121 for increasing the contact area with the bed surface. The lower cover unit 12 includes a second housing connecting block 124 corresponding to the structure of the first housing connecting block 114 of the upper cover unit, so as to be connected with the upper cover unit 11 by screws, for example, which can include two second middle connecting blocks 1241 for fixing the housing and two second end housing connecting blocks 1242 for closing the housing to prevent the upper cover housing 111 and the lower cover housing 121 from colliding and making noise when the vibrator is working.

[0086] ​The lower cover unit 12 includes a second motor mounting sub-region accommodating the motor 22, and the axial two ends of the second motor mounting sub-region are provided with polygonal limiting blocks 123 for limiting the axial movement of the motor 21. In some embodiments, the lower cover unit 12 provides a circumferentially arranged second annular rib 125 along the inner surface of the lower cover shell 121 at the second motor mounting sub-region to limit the radial movement of the motor 21. In some embodiments, the lower cover unit 12 further includes a motor wire outlet 126 for the motor wires to pass through. In some embodiments, the lower cover unit 12 further includes a second snap-fit groove 127 conforming to the profile of the lower cover shell, which is configured to snap-fit with the first snap-fit groove 117 of the upper cover shell, improving the tightness of the shell.

[0087] After the upper cover shell 111 and the lower cover unit 12 are snap-fitted, the first motor mounting sub-region and the second motor mounting sub-region inside form a complete motor mounting region conforming to the outer profile of the motor.

[0088] In some embodiments, a large-area reinforcing rib 1221 is provided on the lower cover bottom plate 122 of the lower cover unit 12 to improve the stability of the vibrator.

[0089] The upper cover shell 111 and the lower cover unit 12 can be obtained by injection molding of polystyrene (PS), polyoxymethylene (POM), polyolefin (PP), polycarbonate (PC), or nylon (PA), etc.

[0090] As described above, the vibration assembly 20 is mounted inside the shell 10, and includes a motor 21 for providing power, an eccentric block 22 connected to the motor shaft of the motor 21 for providing periodic eccentric force, and an elastic material formed gap elimination component 23 attached to the metal shell of the motor 21 to eliminate the gap between the motor 21 and the upper cover shell 111 and the lower cover shell 121, thereby reducing noise. The vibration assembly 20 further includes wires (not shown) for energizing the motor 21, and can further include a wire clamp (not shown) for cooperating with the wire outlets (116, 126) on the shell 10 to fix the wires and prevent the wires from being damaged due to aging during vibration. After the vibration assembly 20 is completely installed in the shell 10, the upper cover unit 11 and the lower cover unit 12 are fixed as a whole by screws.

[0091] The vibrator 100 in some embodiments of the present application cancels the original elastic wrapping sheet and replaces it with the elastic strip 112 connected to the upper cover unit 11 of the shell 10, thereby reducing the assembly man-hours on the wrapping sheet.

[0092] As Figure 7AAs shown in FIG. B, the elastic body 112 can include a fixing portion, such as a cylindrical fixing portion 1120, for fixing directly or indirectly to the bed plate 300. For example, by means of a through hole 1120A thereon fitting into the positioning portion 201 of the fixing plate 200 and then fixing to the bed plate 300. It should be understood that in embodiments without the fixing plate 200, the cylindrical fixing portion 1120 is fixed directly to the bed plate. The configuration of the cylindrical fixing portion 1120 can be a cylinder, or can be a prism, or can be other solid configurations, without limitation, as long as positioning and fixing can be achieved, such as by means of a through hole provided therebetween.

[0093] As described above, the elastic body 112 is fixed to the upper cover housing 111. As shown in FIG. 6A, the elastic body 112 further includes a fixing portion 1121 for fixing to the fixing plate 200. The fixing portion 1121 can be fixed to the fixing plate 200 in any manner. For example, direct surface fixing. In some embodiments, such as shown in FIG. 6B, the fixing portion 1121 is a through hole, and the fixing plate 200 is provided with a positioning portion 201 corresponding to the through hole 1121. The through hole 1121 is fixed to the positioning portion 201 of the fixing plate 200, and the elastic body 112 is fixed to the fixing plate 200. Figure 8A 、 Figure 8B As shown in FIG. 6A, the elastic body 112 further includes an upper cover positioning portion 1122 fixed to the upper cover unit 11. The upper cover positioning portion 1122 can be fixed to the upper cover housing 111 in any manner. For example, direct surface fixing. In some embodiments, such as shown in FIG. 6B, the upper cover positioning portion 1122 is a through hole, and the upper cover housing 111 is provided with a positioning portion 1111 corresponding to the through hole 1122. The through hole 1122 is fixed to the positioning portion 1111 of the upper cover housing 111, and the elastic body 112 is fixed to the upper cover housing 111. Figure 6A 、 6B 、6C、 Figure 9A 、 Figure 9B 、 Figure 10 、 Figure 11In the embodiment shown in which the upper cover positioning channel 119 is provided on the upper cover housing, the upper cover positioning portion 1122 can be provided as an outer upper cover positioning portion 1122A located on the outside of the upper cover housing, an inner upper cover positioning portion 1122B located on the inside of the upper cover housing, also referred to as a draw stud, and an upper cover positioning connecting portion 1122C connecting the outer upper cover positioning portion 1122A and the inner upper cover positioning portion 1122B through the positioning channel 119. The outer upper cover positioning portion 1122A can be generally configured as a quadrangular prism, for example, with an end face conforming to the surface profile of the upper cover housing on the side engaging the upper cover housing, and the inner upper cover positioning portion 1122B can be a sheet-like structure with a certain thickness, for example, generally trapezoidal in shape. The upper cover positioning connecting portion 1122C can be a strip-like structure filling the entire groove, with an upper end face engaging the outer upper cover positioning portion 1122A and a lower end face engaging the inner upper cover positioning portion 1122B. In an embodiment in which the positioning channel 119 is one, the upper cover positioning connecting portion 1122C needs to have high strength to avoid being pulled apart, and the inner upper cover positioning portion 1122B needs to have high deformation resistance to avoid being pulled out of the positioning channel 119 to the outside of the upper cover housing. In an embodiment in which the positioning channel 119 is two, for example, two positioning channels 119 arranged in parallel or at an angle, the upper cover positioning connecting portion 1122C is two, engaging different positions of the outer upper cover positioning portion 1122A and the inner upper cover positioning portion 1122B, respectively, thereby forming a more stable structure, at which time only the inner upper cover positioning portion 1122B and the upper cover positioning connecting portion 1122C need to have a certain strength.

[0094] The inner upper cover positioning portion 1122B formed inside the upper cover housing can increase the force receiving area, reduce the force at the upper cover housing of the outer upper cover positioning portion 1122A, and prevent the upper cover positioning portion 1122 from falling off due to excessive load. The inner upper cover positioning portion 1122B is provided in a generally trapezoidal body structure to ensure normal rotation of the vibrator motor eccentric block while reducing the stress at the upper cover housing and the elastic body connection, preventing the elastic body from falling off due to insufficient adhesion to the upper cover housing.

[0095] In an embodiment in which the upper cover housing has an upper cover positioning column 118 as shown in FIG. 6, the outer upper cover positioning portion 1122A can be provided with a corresponding fitting hole 1122D, so that the positioning column 118 can pass through the end of the outer upper cover positioning portion 1122A, and the end of the upper cover housing 111 has an upwardly protruding cylindrical column 118 mainly for increasing the adhesion area of the upper cover positioning portion of the elastic body 112 to the upper cover housing 111, reducing the stress of the elastic body on both sides when under stress, thereby further ensuring the engagement of the upper cover positioning portion 1122 and the upper cover housing.

[0096] AsFigure 10 As shown, the elastic body 112 further comprises an elastic section 1121 extending between the cylindrical fixing portion 1120 and the upper cover positioning portion 1122. Unlike the cylindrical fixing portion 1120 and the upper cover positioning portion 1122, the elastic section 1121 has an elongated configuration, in some embodiments, the elastic section 1121 may, for example, have the same cross section, for example, an elongated cylinder or a prism.

[0097] In other embodiments, the elastic section 1121 can comprise multiple subsections having different configurations. For example, the elastic section 1121 can comprise a first elastic subsection 1121A having an elongated cylinder or prism configuration, and a second elastic subsection 1121B having a substantially cuboid configuration with a lateral dimension greater than that of the first elastic subsection 1121A. The lateral dimension of the second elastic subsection 1121B can be substantially the same as that of the upper cover positioning portion 1122, while its thickness can be less than that of the upper cover positioning portion 1122 and less than that of the first elastic subsection 1121A, i.e., the Z-direction dimension. The first elastic subsection 1121A of the cylinder is the main area of tensile deformation, providing the elastic body 112 with stress in the X-direction, i.e., the axial direction, the Y-direction, i.e., the lateral direction, and the Z-direction, i.e., the thickness direction; the second elastic subsection 1122B has a smaller cross section due to its smaller thickness, i.e., Z-direction dimension, and thus is more easily bent and deformed, causing the elastic body 112 to generate an upward component force; meanwhile, the cross section of the upper cover positioning portion 1122 has a greater thickness, which reduces the deformation in the thickness direction, i.e., the Z-direction, at the connection between the upper cover positioning portion 1122 and the upper cover shell 111, thereby reducing the stress at the connection.

[0098] As shown in FIG. 1, the elastic body 112 is arranged to be in contact with the upper cover shell 111, and the upper cover positioning portion 1122 is arranged to be in contact with the upper cover shell 111. Figure 7A , Figure 7B , Figure 9A As shown in FIG. 1, the elastic body 112 is arranged to be in contact with the upper cover shell 111, and the upper cover positioning portion 1122 is arranged to be in contact with the upper cover shell 111.

[0099] As shown in FIG. 1, the elastic body 112 is arranged to be in contact with the upper cover shell 111, and the upper cover positioning portion 1122 is arranged to be in contact with the upper cover shell 111. Figure 4 , Figure 16 , Figure 17As shown, the four elastic bodies 112 are arranged in pairs in axial symmetry, so that the resultant force of the elastic forces (i.e. pulling forces) F1, F2, F3, F4 generated by the four elastic bodies is balanced with the pressure P from above and the gravity G of the vibrator. The extensions P1, P2, P3, P4 of the directions of the four elastic body pulling forces F1, F2, F3, F4 intersect on the two central axes A1, A2 of the vibrator. It has been proven in practice that the larger the area P enclosed by the extensions P1, P2, P3, P4, the more stable the vibrator is in operation and the less likely it is to experience deflection.

[0100] In some embodiments of the present application, the elastic strips 112 are made of one material throughout, such as thermoplastic elastomer (TPE for short) or plastic, or thermoplastic rubber (TPR for short), or silicone, rubber, etc., preferably thermoplastic elastomer. Alternatively, the elastic strips 112 are made of more than one material throughout.

[0101] In some embodiments, the vibration plate is combined with the housing 10 to form part of the lower cover unit 12, which can reduce the assembly time of the vibration plate and reduce the vibration between the vibration plate and the vibration motor.

[0102] As shown in FIG. 12, when the vibrator 100 is installed on the bed plate 300 of an electric bed, the lower cover unit 12 of the vibrator 100 bears the pressure from above the bed plate 300, and the four elastic bodies 112 on the upper cover unit 11 of the vibrator 100 generate upward components of force by deforming to counteract the weight of the vibrator 100 and the pressure from above the bed plate 300. When the vibration assembly 20 rotates periodically, the required upward pulling force also varies in size, and the elastic bodies 112 stretch to different lengths, causing the surface of the electric bed to periodically fluctuate up and down at the positions directly contacting the vibrator 100, thereby forming vibrations, and the strength of the vibrations is determined by the rotation speed of the motor 21 and the mass of the eccentric block 21 in the vibrator 100 and the elasticity of the buffer elastic body 23.

[0103] When the vibrator 100 is installed on the bed plate 300 of an electric bed, the elastic bodies 112 are already stretched and have internal stress. When the bed plate bears a large weight, the elastic bodies 112 can deform or the deformation can be aggravated, thereby causing the stress at the connection between the elastic bodies 112 and the upper cover unit 11 to increase sharply and the stretched length of the elastic bodies 112 to increase.

[0104] As shown in FIG. 13, the vibrator 100 can be directly fixed to the bed plate 300 by means of the four elastic bodies 112 through screws. Alternatively, as shown in FIG. 14, the vibrator 100 can be directly fixed to the bed plate 300 by means of the four elastic bodies 112 through bolts. Figure 13A Figure 14A ​As shown, the mounting fixing plate 200 can be provided for the vibrator 100, and the four elastic bodies 112 of the vibrator 100 are fixed on the mounting fixing plate 200, and then the mounting fixing plate 200 is fixed on the bed plate to indirectly fix the vibrator 100 on the bed plate 300.

[0105] As shown, when the vibrator 100 is mounted on the bed plate 300, the positioning grooves 312 can be positioned at the positions corresponding to the four elastic bodies 112 at the four corners of the vibrator mounting hole 301 of the bed plate 300, and the worker can position the vibrator 100 through the positioning grooves 312 during the mounting of the vibrator 100, so as to prevent the vibrator from being mounted incorrectly. Figure 13B

[0106] In addition, since the bottom surface of the bed plate 300 of the electric bed is usually paved with the fabric 400, the bottom surface of the vibrator 100 is prone to expose the original color of the wood plate without the mounting fixing plate 200, and further processing of the fabric of the bed plate 300 is required at this time.

[0107] The processing of the fabric can include the following steps: step S131, cutting the fabric 400 at the positions 401 corresponding to the bottom of the vibrator 100 to be mounted to obtain the configuration as shown in Figure 13C Step S132, folding down the four cut fabric parts 4011 of the fabric 400 and turning over the bed plate 300 to obtain the configuration as shown in Figure 13D Step S133, fixing the bottom fabric at the bending line of the bed surface 200, for example, using the tacks 4012 to obtain the configuration as shown in Figure 13E Step S134, inserting the longer cut fabric part into the other side of the bed plate to make it conform to the surface of the bed plate, so that only the tacks 4012 are visible on the other side, to obtain the configuration as shown in Figure 13F , Figure 13G Step S135, during the mounting of the vibrator, the worker can assemble the vibrator by sensing the positioning grooves 312 covered by the fabric 400 on the bed plate to obtain the configuration as shown in Figure 13F The above-described fixing with tacks can also be replaced by an adhesive. The above-described fixing of the longer cut fabric part into the other side of the bed plate can also be replaced by an adhesive.

[0108] A preferred structure of the mounting fixing plate 200 is as shown in Figure 14B , Figure 15A , Figure 15B , Figure 15C ​As shown, the mounting fixing plate 200 is a substantially rectangular frame structure, the size of which conforms to the size of the vibrator. The mounting fixing plate 200 can include positioning portions 201 located at the four corners of the rectangular frame structure, and four edge frame strips 202 connecting the four positioning portions 201. The positioning portion 201 is provided with a positioning groove 2011 for the elastic strip of the vibrator, each positioning groove 2011 is matched with the cylindrical fixing portion 1120 of one elastic strip 112 of the upper cover unit 11 to position it, and then the cylindrical fixing portion 1120 of the elastic strip and the mounting fixing plate 200 can be connected to the bed plate 30 at this position through a screw. This positioning groove structure also facilitates the taking and placing of the vibrator. There is a downwardly protruding fixing frame positioning block 202 on each of the four edge frame strips 203 of the mounting fixing plate 200. The fixing frame positioning block 202 can quickly position the mounting fixing plate 2100 and the opening of the bed plate 300, preventing the vibrator 100 from being incorrectly installed. In some embodiments, reinforcing ribs 2031 can be provided on the edge frame strips 203.

[0109] In some embodiments, the edge frame strips of the mounting fixing plate 200 further include upwardly protruding and laterally extending fixing plate wire clamps 204. The fixing plate wire clamps 204 can fix the wires of the vibration assembly 20, preventing the vibration of the wires during the operation of the vibrator, the aging of the wires, and the noise caused by the collision of the wires and the bed frame bed plate.

[0110] Some other embodiments of the present application also provide a forming method of a vibrator, which includes forming the upper cover unit 11 by using a two-shot injection molding method.

[0111] In the process, any one of the above-mentioned engineering plastics is first used to injection mold the upper cover shell 111, and then the elastic material is injection molded on the formed upper cover shell 111. Since the two materials are formed by batch injection molding, the combination degree of the two is higher than that of the assembled plastic parts. This way reduces the assembly time of the elastic strip and the plastic shell, reduces the labor hours, reduces the cost, and is more convenient for industrialized mass production.

[0112] The upper cover shell formed by the initial injection molding is separately or in combination with the positioning column 118 and the positioning channel 119 for contacting the elastic body as described above. The positioning column 118 is, for example, a cylindrical column and / or a square column, wherein the positioning column can increase the contact area with the elastic body, and increase the firmness of the elastic body 112 and the upper cover shell 111. The positioning channel 119 can be provided adjacent to the positioning column 118, and the positioning channel can be a long strip-shaped groove, or a circular or square hole.

[0113] The formation of the upper cover positioning portion 1122 of the elastic strip 112 during secondary injection molding is particularly important. Grooves or holes allow the molten material of the elastomer, such as molten TPE liquid, to pass through the upper cover shell 111 after the outer upper cover positioning portion 1122A (also known as the pull strip) is formed on the outer side of the upper cover shell. This allows the inner portion of the upper cover positioning portion 1122B (also known as the pull strip) to be formed on the inner side. Furthermore, an upper cover positioning connection portion 1122C connecting the outer upper cover positioning portion 1122A and the inner upper cover positioning portion 1122B is formed within the grooves or holes. After secondary injection molding, elastic strip 112 material exists on both the inner and outer sides of the upper cover shell 111 of the upper cover unit 11. The inner upper cover positioning portion 1122B formed by the inner material primarily serves to increase the connection area and reduce stress at the contact point between the two parts. This structure helps reduce the stress on the elastomer 112 and the plastic cover shell 111, increases the load-bearing capacity of the elastomer, extends the service life of the elastomer, and thus extends the service life of the entire vibrator.

[0114] It should be understood that the shape of the upper cover positioning connection 1122C is determined by the positioning channel 119. For example, when the positioning channel is groove-shaped, the upper cover positioning connection 1122C is strip-shaped; while when the positioning channel is a positioning hole, the upper cover positioning connection 1122C is column-shaped. As mentioned above, multiple groove-shaped positioning channels 119 can be provided, thereby forming multiple strip-shaped upper cover positioning connections 1122C connecting the outer upper cover positioning part 1122A and the inner upper cover positioning part 1122B. Alternatively, multiple hole-shaped positioning channels 119 can also be provided, thereby forming multiple column-shaped upper cover positioning connections 1122C connecting the outer upper cover positioning part 1122A and the inner upper cover positioning part 1122B.

[0115] It should be understood that the shape of the inner upper cover positioning part 1122B is not particularly limited. For example... Figure 11 As shown, in an example where the inner upper cover positioning part 1122B extends into the eccentric block operating area within the upper cover housing 111, the eccentric block operating area is an area axially adjacent to the motor mounting sub-area. In this case, setting the inner upper cover positioning part 1122B to a trapezoidal shape helps to adapt to the shape of the outer upper cover positioning part 1122A (i.e., the pull bar), reducing the stress at the connection between the upper cover housing and the elastic body, thereby increasing the connection strength between the inner upper cover positioning part 1122B (i.e., the pull bar) and the housing, while leaving operating space for the eccentric block on the motor of the vibration assembly to ensure its normal rotation.

[0116] The foregoing description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein can be applied to other embodiments without departing from the spirit or scope of the application. Thus, the present application is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0117] Moreover, while advantages associated with some implementations of the technology have been described in the context of those implementations, other implementations can also exhibit such advantages, and not all implementations need necessarily exhibit such advantages to fall within the scope of the technology. Accordingly, the disclosure and associated technology can include other implementations that are not expressly shown or described herein. Thus, the disclosure is not intended to be limited to the implementations shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An integrated injection molding vibrator, characterized in that: The device includes a housing and a vibration assembly, wherein the housing is formed by an upper cover unit and a lower cover unit; wherein the upper cover unit is formed by joining an upper cover shell and multiple elastic strips, and the lower cover unit is formed by a lower cover shell and a base plate; the elastic strips are injection molded onto the upper cover shell. The upper cover unit includes a first housing connecting block for connecting to the lower cover by screws, which includes two first middle connecting blocks for fixing the housing, and / or two first end connecting blocks for further closing the two housings; the lower cover unit includes a second housing connecting block, which corresponds to the structure of the first housing connecting block of the upper cover unit, including two second middle connecting blocks for fixing the housing, and two second end housing connecting blocks. The elastic strip is fixed to the upper cover housing, including a fixing part for directly or indirectly fixing to the bed board, an upper cover positioning part fixed to the upper cover unit, and an elastic segment extending between the fixing part and the upper cover positioning part; A positioning channel is provided on the upper cover housing for connecting the elastic strip; the upper cover positioning part is configured to include an outer upper cover positioning part located outside the upper cover, an inner upper cover positioning part located inside the upper cover, and an upper cover positioning connecting part that passes through the positioning channel and connects the outer upper cover positioning part and the inner upper cover positioning part; The outer upper cover positioning part is a quadrangular prism with an end face conforming to the surface contour of the upper cover on the side that engages with the upper cover. The inner upper cover positioning part has a sheet-like structure. The upper cover positioning connecting part is a strip-like structure that fills the entire groove, with its upper end face engaging the outer upper cover positioning part and its lower end face engaging the inner upper cover positioning part. The elastic segment is a first elastic segment with a slender cylindrical or prismatic configuration, and a second elastic segment with a cuboid configuration whose lateral dimension is larger than that of the first elastic segment. The lateral dimension of the second elastic segment is the same as that of the upper cover positioning part, but its thickness is less than that of the upper cover positioning part and less than that of the first elastic segment. The elastic segment comprises multiple segments with different configurations; A third elastic segment with a gradually varying thickness or a segmented varying thickness is provided between the second elastic segment and the upper cover positioning portion.

2. The integrated injection molding vibrator according to claim 1, characterized in that: The upper cover unit includes a first motor mounting sub-region with polygonal limiting blocks at both axial ends; a first annular rib arranged circumferentially along the inner surface of the upper cover in the first motor mounting sub-region; the lower cover unit includes a second motor mounting sub-region for accommodating a motor, with polygonal limiting blocks at both axial ends of the second motor mounting sub-region to restrict the axial movement of the motor; the lower cover unit includes a second annular rib arranged circumferentially along the inner surface of the lower cover housing in the second motor mounting sub-region to restrict the radial movement of the motor; after the upper cover housing and the lower cover housing are fastened together, a complete motor mounting area conforming to the outer contour of the motor is formed in the first motor mounting sub-region and the second motor mounting sub-region inside.

3. The integrated injection molding vibrator according to claim 1, characterized in that: The lower cover unit includes a lower cover housing for accommodating the vibration assembly and a lower cover base plate extending laterally from the bottom surface of the lower cover housing to increase the contact area with the bed surface.

4. The integrated injection molding vibrator according to claim 3, characterized in that: The bottom plate of the lower cover unit is provided with a large area of ​​reinforcing ribs to improve the stability of the vibrator.

5. The integrated injection molding vibrator according to claim 1, characterized in that: The inner upper cover positioning part has a trapezoidal structure.

6. The integrated injection molding vibrator according to claim 1, characterized in that: For each elastic strip, the positioning channel is one, two, or more grooves or holes penetrating the upper cover housing.

7. The integrated injection molding vibrator according to claim 6, characterized in that: The positioning channel consists of two grooves, and the upper cover positioning connection part consists of two parts, which respectively engage different positions of the outer upper cover positioning part and the inner upper cover positioning part.

8. The integrated injection molding vibrator according to claim 1, characterized in that: The upper cover housing has an upper cover positioning post, and the outer upper cover positioning part provides a corresponding mating hole so that the positioning post passes through the end of the outer upper cover positioning part and engages with the upper cover positioning part.

9. The integrated injection molding vibrator according to claim 1, characterized in that: There are four elastic strips, arranged symmetrically in pairs on the upper cover shell, so that the resultant force of the first elastic force (F1), the second elastic force (F2), the third elastic force (F3), and the fourth elastic force (F4) generated on the four elastic strips is balanced with the pressure above (P) and its own weight (G).

10. The integrated injection molding vibrator according to claim 9, characterized in that: The first extension line (P1), second extension line (P2), third extension line (P3), and fourth extension line (P4) of the directions of the first elastic force (F1), second elastic force (F2), third elastic force (F3), and fourth elastic force (F4) of the four elastic bars converge on the two central axes of the vibrator.

11. The integrated injection molding vibrator according to claim 10, characterized in that: The area (P) enclosed by the first extension line (P1), the second extension line (P2), the third extension line (P3), and the fourth extension line (P4) is greater than 10% of the cross-sectional area of ​​the vibration motor.

12. The integrated injection molding vibrator according to claim 1, characterized in that: The entire elastic strip is made of a single material, including thermoplastic elastomers.

13. The integrated injection molding vibrator according to claim 1, characterized in that: The vibrator is directly fixed to the bed board with screws.

14. The integrated injection molding vibrator according to claim 1, characterized in that: It also includes a mounting plate, through which the vibrator is indirectly fixed to the bed board.

15. The integrated injection molding vibrator according to claim 14, characterized in that: The mounting plate is a rectangular frame structure, including positioning parts located at the four corners of the rectangular frame structure, and four side strips connecting the four positioning parts; wherein, the positioning part is provided with positioning grooves for the elastic strips of the vibrator, and each positioning groove matches a fixing part of an elastic strip of the upper cover.

16. The integrated injection molding vibrator according to claim 15, characterized in that: There are downward protruding fixing bracket positioning blocks on the four side strips of the mounting plate. These fixing bracket positioning blocks can be used to quickly position the mounting plate at the opening of the bed board.

17. The integrated injection molding vibrator according to claim 16, characterized in that: The border strip is provided with reinforcing ribs.

18. The integrated injection molding vibrator according to claim 17, characterized in that: The mounting plate also includes an upwardly protruding and laterally extending mounting plate wire clip on its frame strip.

19. The integrated injection molding vibrator according to claim 18, characterized in that: The vibration assembly is installed inside the housing, and includes a motor for providing power; an eccentric block connected to the motor shaft for providing periodic eccentric force; and a gap-eliminating component formed of elastic material attached to the metal housing of the motor to eliminate gaps between the motor and the upper and lower housings.

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