Mold, method for manufacturing a foamed article, foamed article and vehicle seat

Abstract

The present application relates to a mold for manufacturing a foamed article, wherein the mold comprises a mold body and a tines sheet assembly which is detachably arranged on the mold body, wherein a front side of the tines sheet assembly, which faces away from the mold body, comprises a tine face, and wherein the tines sheet assembly is configured to releasably hold a skin material of the foamed article on the mold body by means of the tine face. The present application further relates to a method for manufacturing a foamed article, to a foamed article and to a vehicle seat.

Description

Technical Field

[0001] This application relates to a mold for manufacturing foamed articles, a method for manufacturing foamed articles, a foamed article, and a vehicle seat. Background Technology

[0002] Foamed products are widely used in construction, packaging, furniture, automotive, and medical fields. For example, foamed products can be used as filling material in furniture seats or vehicle seats to provide the necessary support and comfort. These foamed products may be primarily / made of materials such as polyurethane foam or rubber foam and may at least partially include a surface material, such as nonwoven fabric, to improve the strength of the foamed product and / or prevent noise, for example, that may occur when the foamed product contacts and rubs against the seat frame.

[0003] When manufacturing such foamed products with a surface material, the surface material must first be fixed in the foaming mold, and then the foaming material is injected into the mold so that the foaming material and the surface material are integrally formed. Figure 1 A method known in the prior art for fixing surface material in a foaming mold is shown, wherein a magnet 501 is provided in the cavity surface of the foaming mold 500, and an iron powder film 503 is provided on the side of the surface material 502 facing away from the cavity surface. The surface material can be attracted and held in the foaming mold by means of the attraction between the iron powder film and the magnet. Here, the surface material is located between the iron powder film and the foaming mold. When foaming material is filled into the mold cavity, the foaming material surrounds the iron powder film and integrally molds the iron powder film together into a foamed article. That is, in the above-described method, the iron powder film is retained in the foamed article and exists as part of the foamed article.

[0004] However, due to the increase in functions and the demand for appearance, the surface shape of foamed products is becoming more and more complex. In order to ensure the desired surface shape of the foamed products, a large amount of iron powder film is required to hold the surface material in the foaming mold for each foamed product, which undoubtedly increases the production cost of foamed products.

[0005] Therefore, a solution that can address the above problems is urgently needed. Summary of the Invention

[0006] The objective of this application is to provide a mold for manufacturing foamed articles, a method for manufacturing foamed articles, a foamed article, and a vehicle seat, which can overcome at least one defect in the prior art, thereby particularly reducing the production cost of foamed articles while maintaining or further improving the production efficiency of foamed articles.

[0007] The task is accomplished through a mold for manufacturing foamed products, a method for manufacturing foamed products, a foamed product, and a vehicle seat.

[0008] The first aspect of this application relates to a mold for manufacturing foamed articles, wherein the mold includes a mold body and a bristle assembly detachably disposed on the mold body, wherein when the bristle assembly is connected to the mold body, the front side of the bristle assembly opposite to the mold body includes a burred surface, and the bristle assembly is configured to detachably retain the surface material of the foamed article on the mold body by means of the burred surface.

[0009] According to one embodiment of this application, the bristle assembly is disposed magnetically and / or adhesively and / or mechanically on the surface of the mold body, particularly the cavity of the mold.

[0010] According to one embodiment of this application, the bristle assembly includes a bristle with the bristle surface and a magnetic element fixed to the bristle, the mold body includes a magnet, and the magnetic element and the magnet are magnetically attracted to each other.

[0011] According to one embodiment of this application, the bristle assembly includes a back substrate, and the bristles, magnetic elements and the back substrate are stacked sequentially.

[0012] According to one embodiment of this application, the bristles, magnetic element, and back substrate are bonded together.

[0013] According to one embodiment of this application, the bristles are connected to each other, particularly directly connected to each other, and a magnetic element is clamped between the bristles and the back substrate.

[0014] According to one embodiment of this application, the barbs and the back substrate are connected to each other in a form-locking, force-locking and / or material-locking manner.

[0015] According to one embodiment of this application, the bristles are ultrasonically welded to the back substrate.

[0016] According to one embodiment of this application, the bristle tabs and / or the magnetic element and / or the back-side substrate are respectively constructed as sheets. Within the scope of this application, "sheet-like" can be understood as the thickness of the corresponding component being much smaller than its length and width.

[0017] According to one embodiment of this application, the bristles and the back substrate extend at least partially beyond the edge of the magnetic element, and the bristles and the back substrate are directly connected to each other in the region extending beyond the edge of the magnetic element.

[0018] According to one embodiment of this application, the barbs and the back substrate completely cover the magnetic element and extend beyond the magnetic element over its entire outer periphery.

[0019] According to one embodiment of this application, the magnetic component includes permanent magnet material and / or ferromagnetic material.

[0020] According to one embodiment of this application, the magnetic component is constructed as a permanent magnet material sheet and / or a ferromagnetic material sheet.

[0021] According to one embodiment of this application, the magnetic component is constructed as a sheet made of permanent magnet material powder and / or ferromagnetic material powder and rubber, the sheet being flexible and bendable.

[0022] According to one embodiment of this application, the bristles and / or the back-side substrate are made of nylon or polypropylene.

[0023] According to one embodiment of this application, the bristle assembly can be attached to the mold body by means of double-sided tape and / or adhesive.

[0024] According to one embodiment of this application, the double-sided tape and / or adhesive is heat-resistant. Within the scope of this application, "heat-resistant" can be understood in particular as the ability of the corresponding double-sided tape and / or adhesive to withstand temperatures of at least 100°C, particularly at least 150°C, and to maintain its adhesive properties and structural integrity at such temperatures without significant decomposition, melting, hardening, or failure.

[0025] According to one embodiment of this application, the barb assembly is connected to the mold body by means of a connector, the mold body including a mating portion for the connector.

[0026] According to one embodiment of this application, the connector includes an external thread, and the mating portion includes an internal thread for engaging with the external thread; and / or the connector includes a locking portion, and the mating portion includes a mating locking portion for engaging the locking portion.

[0027] According to one embodiment of this application, the connector and the bristle assembly are constructed as a single piece.

[0028] According to one embodiment of this application, the connector is injection molded, welded, or bonded to the bristle assembly.

[0029] According to one embodiment of this application, the connector and the bristle assembly are constructed independently of each other.

[0030] According to one embodiment of this application, the connector is constructed as a bolt, such as a countersunk screw.

[0031] According to one embodiment of this application, the mold includes a spring-loaded quick-change mechanism for the bristle assembly.

[0032] According to one embodiment of this application, the bristle assembly has a circular, polygonal (e.g., rectangular, square, hexagonal, etc.) or irregular shape; and / or the maximum extension dimension of the bristle assembly is 5 mm to 100 mm, preferably 10 mm to 50 mm; and / or the thickness of the bristle assembly is 0.5 mm to 6 mm, preferably 1 mm to 3 mm.

[0033] According to one embodiment of this application, a recess is constructed in the mold body that is recessed relative to the cavity surface of the mold, the recess being configured to accommodate a barb assembly.

[0034] According to one embodiment of this application, the recess has a shape corresponding to the bristle assembly; and / or the depth of the recess is adapted to the thickness of the bristle assembly, such that when the bristle assembly is accommodated in the recess, the burr surface of the front side of the bristle assembly is not lower than, and in particular slightly higher than, the cavity surface of the mold. In some embodiments, the height of the burr surface of the bristle assembly relative to the cavity surface may substantially correspond to the height of the burr structure of the burr surface.

[0035] According to one embodiment of this application, the mold includes a plurality of barb assemblies, which are distributed at a distance from each other on the cavity surface of the mold.

[0036] According to one embodiment of this application, the density of the bristle assembly in a first region of the cavity surface of the mold is less than the density of the bristle assembly in a second region of the cavity surface of the mold, and the flatness of the first region is greater than the flatness of the second region.

[0037] According to one embodiment of this application, the foamed article is a foamed article for use in seats; and / or the surface material is a nonwoven fabric.

[0038] According to one embodiment of this application, the force between the burr surface and the surface material is less than the force between the burr assembly and the mold body.

[0039] According to a second aspect of this application, therein is a method for manufacturing foamed articles, wherein the foamed articles are manufactured using a mold as described in the first aspect of this application.

[0040] According to one embodiment of this application, the method includes at least one of the following steps:

[0041] a. Install the barbed wire assembly on the mold body;

[0042] b. Maintain the surface material of the foamed product on the bristle assembly;

[0043] c. Foaming molding;

[0044] d. Remove the foamed product from the mold, preferably with the bristle assembly held on the mold body during the process.

[0045] According to one embodiment of this application, step a includes: setting the barb assembly on the mold body in a magnetic and / or adhesive and / or mechanical manner.

[0046] According to one embodiment of this application, step a includes at least one of the following steps:

[0047] The barb assembly is magnetically attached to the surface of the mold cavity;

[0048] The barb assembly is attached to the cavity surface of the mold using double-sided tape and / or adhesive.

[0049] The burr assembly is set on the cavity surface of the mold using a connector;

[0050] The barb assembly is set on the cavity surface of the mold by means of a spring-loaded quick-change mechanism.

[0051] According to one embodiment of this application, step a is performed before step b, and step b includes:

[0052] A force is applied from at least one side of the surface material away from the cavity surface to the functional area of ​​the surface material for attachment to the bristle assembly, such that at least said functional area of ​​the surface material is attached to the bristle assembly, thereby setting the surface material on the cavity surface of the mold.

[0053] According to one embodiment of this application, the surface material used in step b is a pre-treated surface material, the pre-treatment including at least one of machining, sewing, welding, and thermoforming. The surface material to be applied to the cavity surface of the mold may include, but is not limited to, surface materials produced by machining such as stamping (e.g., 2D nonwoven fabric), surface materials produced by stamping followed by sewing or welding, or surface materials thermoformed (e.g., 3D nonwoven fabric).

[0054] According to one embodiment of this application, step d refers to separating the foamed article from the bristle assembly.

[0055] According to one embodiment of this application, the method further includes step e: removing the barb assembly from the mold body.

[0056] According to one embodiment of this application, a manufacturing cycle includes at least steps b, c, and d, with step e performed only after a certain number of said manufacturing cycles, the number of said manufacturing cycles being between 100 and 5000, for example, between 200 and 2000.

[0057] According to one embodiment of this application, at least one step of the method is performed manually and / or automatically.

[0058] According to a third aspect of this application, therein lies a foamed article comprising a surface material having functional regions, particularly a plurality of functional regions, for attachment to a bristle assembly. In some embodiments, one functional region may be used for attachment to a corresponding bristle assembly.

[0059] According to one embodiment of this application, in the functional region, the height by which the fibers of the surface material extend beyond the surface of the surface material is greater than that in other regions; and / or in the functional region, the average fiber length of the surface material is greater than the average fiber length in other regions; and / or in the functional region, the surface fiber density of the surface material is lower than that in other regions.

[0060] According to one embodiment of this application, the foamed article has a recess in the functional area, the shape of which substantially corresponds to the shape of the bristle assembly.

[0061] According to one embodiment of this application, at least in the functional area, there are no permanent magnet sheets and / or ferromagnetic sheets between the foaming material and the surface material of the foamed article.

[0062] According to one embodiment of this application, in the foamed article, the number of permanent magnet material sheets and / or ferromagnetic material sheets is less than the number of the functional areas.

[0063] According to one embodiment of this application, there are no permanent magnet material sheets and / or ferromagnetic material sheets in the foamed article.

[0064] According to one embodiment of this application, the foamed article is manufactured by means of a mold as described in the first aspect of this application, and / or the foamed article is manufactured by means of a method as described in the second aspect of this application.

[0065] According to one embodiment of this application, the foamed article is a foamed article for use in seats; and / or the surface material is a nonwoven fabric.

[0066] According to one embodiment of this application, the foamed article is a foamed article for vehicle seats, and the surface material is located at least on the back side of the foamed article.

[0067] According to a fourth aspect of this application, therein is a vehicle seat comprising the foamed article described in a third aspect of this application.

[0068] Other features of this application are derived from the accompanying drawings and the detailed description. All features and combinations thereof mentioned above in the specification, as well as features and combinations thereof mentioned below in the detailed description and / or shown separately in the drawings, can be used not only in the combinations given therefor, but also in other combinations, or in their individual states. Attached Figure Description

[0069] A better understanding of various aspects of this application will be achieved by reading the following detailed description in conjunction with the accompanying drawings, in which:

[0070] Figure 1 This illustrates a method known from the prior art for fixing surface material in a foaming mold;

[0071] Figure 2 A schematic diagram of a mold for manufacturing foamed articles according to some embodiments of this application is shown;

[0072] Figure 3 A schematic diagram of a mold for manufacturing foamed articles according to other embodiments of this application is shown;

[0073] Figure 4 A schematic diagram of a mold for manufacturing foamed articles according to further embodiments of this application is shown;

[0074] Figure 5 A schematic diagram of a bristle assembly according to some embodiments of this application is shown;

[0075] Figure 6 A schematic diagram of a bristle assembly according to other embodiments of this application is shown;

[0076] Figure 7 A top view schematically illustrating a bristle assembly according to some embodiments of this application;

[0077] Figure 8 A bottom view schematically illustrates a bristle assembly according to other embodiments of this application;

[0078] Figure 9 The burr structure of a burr assembly according to some embodiments of this application is schematically shown;

[0079] Figure 10The burr structure of the burr assembly according to other embodiments of this application is schematically shown;

[0080] Figure 11 A portion of a vehicle seat according to some embodiments of this application is schematically shown in cross-sectional view;

[0081] Figure 12 A schematic diagram of the surface material of a foamed product is shown.

[0082] Figure 13 A flowchart illustrating a method for manufacturing foamed articles according to some embodiments of this application is shown schematically.

[0083] Figure 14 A flowchart illustrating a method for manufacturing foamed articles according to other embodiments of this application is shown schematically.

[0084] Figure 15 and Figure 16 The fiber distribution of the surface material of the foamed article in the working area is illustrated by way of example at different magnification scales. Detailed Implementation

[0085] The present application will now be described with reference to the accompanying drawings, which illustrate several embodiments of the present application. However, it should be understood that the present application can be presented in many different ways and is not limited to the embodiments described below; in fact, the embodiments described below are intended to make the disclosure of the present application more complete and to fully illustrate the scope of protection of the present application to those skilled in the art. It should also be understood that the embodiments disclosed herein can be combined in various ways to provide more additional embodiments.

[0086] It should be understood that the terminology used in this specification is for describing specific embodiments only and is not intended to limit this application. All terms used in this specification (including technical and scientific terms) have the meanings commonly understood by those skilled in the art, unless otherwise defined. For the sake of brevity and / or clarity, well-known functions or structures may not be described in detail.

[0087] Unless otherwise specified, the singular forms “a,” “the,” and “the” used in this specification include the plural forms. The terms “comprising,” “including,” and “containing” used in this specification indicate the presence of the claimed feature but do not exclude the presence of one or more other features. The term “and / or” used in this specification includes any and all combinations of one or more of the relevant listed items.

[0088] When a component is described in the specification as being "on", "attached" to, "connected" to, "joined" to, or "in contact" with another component, the component may be directly located on, attached to, connected to, joined to, or in contact with the other component, or there may be an intermediate component present.

[0089] In the specification, spatial relation terms such as "above," "below," "front," "back," "top," and "bottom" describe the relationship between one feature and another in the accompanying drawings. It should be understood that spatial relation terms include not only the orientation shown in the drawings but also the different orientations of the device during use or operation. For example, when the device in the drawings is inverted, a feature previously described as "below" other features can now be described as "above" other features. The device can also be oriented in other ways (rotated 90 degrees or in other orientations), in which case the relative spatial relationships will be explained accordingly.

[0090] Figures 2 to 4 A schematic diagram of a mold 100 for manufacturing foamed articles according to some embodiments of this application is shown as an example. The mold 100 includes a mold body 110, which may include at least one, generally multiple (e.g., two) mold portions, each mold portion collectively surrounding a cavity of the mold 100 by a corresponding cavity surface. In manufacturing the foamed article, foaming material can be injected into the cavity of the mold 100 to form the foamed article, where the surface shape and structure of the resulting foamed article are defined by the cavity surface of the mold 100.

[0091] In some cases, the foamed article to be manufactured may be, for example, at least partially, for example substantially entirely, covered with a surface material 210, such as a nonwoven fabric. Therefore, in manufacturing such a foamed article, it may be desirable to at least partially, for example substantially entirely, cover and retain the surface material 210 over the entire mold body 110, particularly the entire cavity surface. In other cases, the foamed article to be manufactured may have the surface material 210 only in certain sections. Therefore, in manufacturing such a foamed article, it may be desirable to retain the surface material 210 only in the regions of the mold body 110, particularly the cavity surface, corresponding to the sections of the foamed article to which the surface material 210 is to be present. In either case, the technical solutions proposed in this application are applicable.

[0092] For clarity, in Figures 2 to 4 Only one mold portion 111 of the mold body 110 is schematically shown. This mold portion 111 may have a cavity surface 112 that (at least partially) defines the cavity 113 of the mold 100. In manufacturing foamed articles, it is desirable, for example, to retain the surface material 210 of the foamed article within the mold body 110, for example... Figure 2 The mold portion 111 shown, especially its cavity surface 112.

[0093] Continue to refer to Figures 2 to 4 To retain the surface material 210 of the foamed article on the mold body 110, the mold 100 includes bristle assemblies 120, preferably a plurality of bristle assemblies 120 spaced apart from each other, detachably disposed (e.g., magnetically and / or adhesively and / or mechanically) on the mold body 110. When the bristle assemblies 120 are disposed on the mold body 110, the front side of the bristle assembly 120 facing away from the mold body 110 includes a burr surface 121. The bristle assembly 120 is configured to detachably retain the surface material 210 of the foamed article on the mold body 110, particularly the cavity surface 112, by means of the burr surface 121.

[0094] Within the scope of this application, the burr assembly 120 "detachably disposed" on the mold body 110 can be understood in particular as a component constructed independently of the mold body 110, which can be held or fixed on the mold body 110, and can also (especially without damaging the mold body 110) be quickly detached or removed from the mold body 110.

[0095] Within the scope of this application, the term "detachably retaining" the surface material 210 of the foamed article on the mold body 110 by means of the burr surface 121 can be understood in particular as meaning that, when the burr assembly 120 is fixed to the mold body 110, the surface material 210 can be (temporarily) retained on the mold body 110 by means of the interaction between the burr surface 121 and the surface material 210 of the foamed article, particularly by means of the burr surface 121 hooking the surface material 210. Here, the detachment or peeling of the surface material 210 from the mold body 110 can be achieved, for example, by separating the surface material 210 from the burr assembly 120.

[0096] In some embodiments, the force 210 between the burr surface 121 and the surface material can be less than the force between the burr assembly 120 and the mold body 110. Thus, for example, after molding the foamed article or when the position of the surface material 210 needs to be adjusted, only the surface material 210 can be peeled off from the burr assembly 120, while the burr assembly 120 itself remains on the mold body 110 for continued use.

[0097] In the mold 100 according to this application, a bristle assembly 120 is advantageously used to hold the surface material 210 of the foamed article on the mold body 110. The bristle assembly 120 can be disposed on the mold body 110 on one hand with a side facing the cavity surface 112, and on the other hand with a bristle surface 121 facing away from the corresponding cavity surface 112 to hold, in particular hook, the surface material 210, so that the bristle assembly 120 can be located between the surface material 210 and the mold body 110 and form a reliable holding interface between the surface material 210 and the mold body 110. The foaming material can be injected into the cavity 113 on the side of the surface material 210 facing away from the corresponding bristle assembly 120. For the foamed article produced by means of mold 100, the bristle assembly 120 is located on the outer side of its surface material 210 opposite to the foamed material, and the bristle assembly 120 can, for example, automatically separate from the foamed article 210 and remain on the mold body 110 during demolding. That is to say, in the technical solution of this application, the bristle assembly 120 does not exist as part of the final foamed article and can be reused in the production process, thereby advantageously reducing the production cost of the foamed article.

[0098] By implementing the technical solution of this application, the use of permanent magnet material sheets and / or ferromagnetic material sheets (e.g., iron powder sheets) in the prior art can be advantageously reduced or even completely eliminated. Furthermore, the bristle assembly 120 can be retained on the mold body 110 and reused when manufacturing the next foamed article without the need for re-laying the bristle assembly 120, thus advantageously meeting the needs of fast-paced production. In addition, in some products, the surface material 210 of the foamed article (generally having a certain degree of transparency) may be at least partially visible to the user, and permanent magnet material sheets and / or ferromagnetic material sheets retained in these areas may affect the appearance of the final product. The technical solution of this application eliminates the need for permanent magnet material sheets and / or ferromagnetic material sheets, which is beneficial to the consistency and aesthetics of the final product's appearance.

[0099] like Figure 2 As shown, in a simple embodiment, the bristle assembly 120 can be attached to the mold body 110 using double-sided tape and / or adhesive. To maintain the adhesiveness of the double-sided tape and / or adhesive at the relatively high operating temperatures (e.g., 150°C) present during the foaming molding process, high-temperature resistant double-sided tape and / or adhesive can be used. Within the scope of this application, "high-temperature resistant" can be understood in particular as the ability of the corresponding double-sided tape and / or adhesive to maintain its adhesive properties and structural integrity at temperatures of at least 100°C, particularly 150°C, without significant decomposition, melting, hardening, or failure. When necessary, the bristle assembly 120 can be removed from the mold body 110, for example, using suitable tools and / or a release agent.

[0100] Alternatively or additionally, in some embodiments, the barb assembly 120 can be magnetically held onto the mold body 110. For example... Figure 3 and Figure 4 As shown, the bristle assembly 120 may include a magnetic element 122 (see [reference]). Figure 5 and Figure 6 The mold body 110 may include a magnet 114, and the magnetic element 122 and the magnet 114 are magnetically attracted to each other, thereby holding the barb assembly 120 on the mold body 110.

[0101] Magnet 114 may be disposed in a region of the mold body 110 near the cavity surface 112 of the mold 100. In some embodiments, such as Figure 3 As shown, a receiving portion 115 for accommodating a magnet 114 can be constructed in the cavity surface 112, and the magnet 114 can be disposed in the receiving portion 115. Here, the surface of the magnet 114 exposed on the mold body 110 can be substantially flush with the cavity surface 112 of the mold 100 or constitute a part of the cavity surface 112 of the mold 100.

[0102] Magnet 114 can be constructed as a permanent magnet (especially a strongly magnetic one) or an electromagnet. Magnet 114 can also be constructed in any suitable shape, such as a cube, cuboid, cylinder, etc. Here, a foaming mold 500 with magnet 501 known in the prior art (see [link to previous section]) is described. Figure 1 It can also be used directly in this application without modifying existing mold equipment or purchasing new mold equipment, thereby effectively reducing the application cost of the technical solution of this application.

[0103] The following is combined with Figure 5 and Figure 6 This application describes some exemplary embodiments of a barb assembly 120 including a magnetic element 122 according to the present application.

[0104] In some embodiments, such as Figure 5 As shown, the bristle assembly 120 may include a bristle 123 with a bristle surface 121 on its front side and a magnetic element 122 fixed, for example, adhered to the back side of the bristle 123. The bristle assembly 120 can be held on the mold body 110 by means of magnetic attraction between the magnetic element 122 and a magnet 114 located on the mold body 110. Both the bristle 123 and the magnetic element 122 may be constructed as sheets. Within the scope of this application, "sheet-like" can be understood as meaning that the thickness of each of the bristle 123 and the magnetic element 122 is much smaller than their respective length and width.

[0105] The magnetic component 122 may comprise permanent magnet materials and / or ferromagnetic materials. Furthermore, the magnetic component 122 may be at least partially in the form of a sheet, such as a sheet of permanent magnet materials and / or ferromagnetic materials. Alternatively or additionally, the magnetic component 122 may also be at least partially in the form of a powder, such as a powder of permanent magnet materials and / or ferromagnetic materials. If the magnetic component 122 comprises powder, such as iron powder, the magnetic component 122 may be formed, for example, by mixing and curing a rubber with the magnetic powder, which is particularly suitable for applications such as... Figure 5 In the situation shown, Figure 5 In this process, the magnetic component 122, formed by mixing and curing rubber with the magnetic powder, can be directly attached to or adsorbed onto the cavity surface 112 of the mold 100 with its side facing away from the bristle piece 123. The magnetic component 122 can be connected to the bristle piece 123 on the other side, for example, by bonding.

[0106] In some embodiments, such as Figure 6 As shown, the bristle assembly 120 may further include a sheet-like back substrate 124. The bristle 123, the magnetic element 122, and the back substrate 124 can be... Figure 6 The components are arranged in a stacked manner from top to bottom, so that the magnetic component 122 is sandwiched between the barbed piece 123 and the back substrate 124. The magnetic component 122 can be connected to the barbed piece 123 on one side, for example, by bonding, and the magnetic component 122 can be connected to the back substrate 124 on the other side, for example, by bonding.

[0107] Continue to refer to Figure 6 The bristle tab 123 and the back substrate 124 may extend at least partially (preferably over the entire outer periphery of the magnetic element 122) beyond the edge of the magnetic element 122. The bristle tab 123 and the back substrate 124 may be connected to each other, particularly directly connected, in the region 125 extending beyond the edge of the magnetic element 122. Here, "directly connected" to each other can be understood in particular as the absence of the magnetic element 122 in the region where the bristle tab 123 and the back substrate 124 are directly connected, or in other words, the bristle tab 123 and the back substrate 124 are not connected to each other via the magnetic element 122 in the region where they are directly connected. The bristle tab 123 may be connected to the back substrate 124 in a form-locking, force-locking, and / or material-locking manner. Specifically, the bristle tab 123 may be bonded to the back substrate 124, for example, by adhesive bonding, welding, or preferably ultrasonic welding. Alternatively or additionally, the barbed strip 123 and the back substrate 124 may each include corresponding connecting structures, such as snap-fit ​​structures, hook structures, etc., in region 125, and the barbed strip 123 and the back substrate 124 may be connected to each other by means of said connecting structures. Alternatively or additionally, the barbed strip 123 and the back substrate 124 may also be connected to each other by means of other elements, such as fastening clips.

[0108] It is understood that the bristle assembly 120 can have any suitable geometry and structure. The bristle assembly 120, particularly its bristle surface 121, can have a circular, polygonal (e.g., rectangular, square, hexagonal, etc.) or irregular shape. Advantageously, the maximum extension dimension of the bristle assembly 120, particularly its bristle surface 121, can be from 5 mm to 100 mm, preferably from 10 mm to 50 mm. It is also advantageous that the thickness of the bristle assembly 120 can be from 0.5 mm to 6 mm, preferably from 1 mm to 3 mm.

[0109] Figure 7 The diagram shows a view of the burr surface 121 of a burr assembly 120 according to some embodiments of this application. Here, the burr 123 can completely cover the magnetic element 122 (not visible in the figure) and extend beyond the magnetic element 122 over its entire outer periphery, thus... Figure 7 Only bristle plates 123 are visible in the view. (Combined) Figure 6 and Figure 7 The bristle tab 123 may have bristle structures 127 (exaggerated in the figures) only in the inner region 126 corresponding to the magnetic element 122, through which a bristle surface 121 is formed. The bristle tab 123 may not have bristle structures 127 forming the bristle surface 121 in the edge region 125 extending beyond the magnetic element 122, thereby facilitating the connection of the bristle tab 123 to the back substrate 124, for example, ultrasonic welding. Here, similar to the bristle tab 123, the back substrate 124 may completely cover the magnetic element 122 and extend beyond the magnetic element 122 over its entire outer periphery. However, this is not a limitation. Figure 8 Looking at the back side of the barb assembly 120 (i.e., the side of the back substrate 124), as... Figure 8 As shown in the left figure, the back substrate 124 may also include, for example, a void 128, in which the magnetic element 122 is exposed in the area of ​​the void 128, so that the back substrate 124 only partially covers the magnetic element 122.

[0110] Figure 8 The right figure illustrates a more general case. Here, the bristle tab 123 (not shown) and the back substrate 124 do not need to completely cover the magnetic element 122, but can only extend partially beyond the edge of the magnetic element 122. The bristle tab 123 and the back substrate 124 can be directly connected to each other in the region 125 extending beyond the edge of the magnetic element 122, thereby holding the magnetic element 122 between the bristle tab 123 and the back substrate 124. In this case, a portion 129 of the magnetic element 122 can be exposed outside the bristle tab 123 and the back substrate 124, that is, a portion 129 of the magnetic element 122 is neither covered by the bristle tab 123 nor by the back substrate 124.

[0111] Advantageously, the barb 123 and / or the back substrate 124 can be made of nylon or polypropylene. Nylon is a commonly used material for manufacturing the barb 123 and is suitable for ultrasonic welding. Furthermore, it is understood that the barb 123 and the back substrate 124 are not required to have the same shape; their shapes and dimensions can be chosen as needed, as long as the magnetic element 122 can be held between them without problems.

[0112] Advantageously, the bristle assembly 120 can be configured to be flexible and bendable. Thus, the bristle assembly 120 can adapt to the curvature of the cavity surface 112 to which it is to be attached, allowing its use even in areas with low flatness or complex surfaces. For this purpose, the bristle 123 and the magnetic element 122 can be configured to be flexible and bendable, and the magnetic element 122 can exist, for example, as a magnetic powder mixed with rubber and then cured to achieve the desired deformability.

[0113] In order to adapt to the curvature of the cavity surface 112, it is also conceivable, for example, a (non-flexible) bristle assembly 120 that is already planar curved, the curvature of which can correspond to the curvature of the cavity surface 112.

[0114] Alternatively or additionally, in some embodiments not shown, the bristle assembly 120 may be connected to the mold body 110 by means of a connector, the mold body 110 including a mating portion for the connector. Specifically, in some embodiments, the connector may include external threads, and the mating portion of the mold body 110 may include internal threads that mate with the external threads. In other embodiments, the connector may include a locking portion, and the mating portion of the mold body 110 may include a mating locking portion corresponding to the locking portion. In some embodiments, the connector may be constructed as a single piece with the bristle assembly 120, for example, the connector may be injection molded, welded, or bonded to the bristle assembly 120, so that the connector may exist as an integral part of the bristle assembly 120. In other embodiments, the connector may be constructed as a separate element independent of the bristle assembly 120. For example, the connector may be constructed as a threaded element, such as a bolt, which can pass through the bristle assembly 120 and be tightened onto the mold body 110, thereby retaining the bristle assembly 120 on the mold body 110.

[0115] In some other embodiments not shown, the mold 100 may include a spring-loaded quick-change mechanism for the barb assembly 120. The spring-loaded quick-change mechanism allows the barb assembly 120 to be fastened to or removed from the mold body 110 by pressing.

[0116] In some embodiments, such as Figure 4 As shown, the mold body 110 may be configured with a recess 116 that is recessed relative to the cavity surface 112 of the mold 100. The recess 116 may be configured to accommodate the bristle assembly 120 and prevent the bristle 120 from moving laterally on the cavity surface 112. The recess 116 may have a shape corresponding to the bristle assembly 120 to be accommodated. Furthermore, the depth of the recess 116 may be adapted to the thickness of the bristle assembly 120, such that when the bristle assembly 120 is accommodated in the recess 116, the bristle surface 121 of the bristle assembly 120 is slightly higher than the cavity surface 112 of the mold 100. This advantageously reduces the influence of the bristle assembly 120 on the actual cavity surface shape and actual cavity shape of the mold 100, because when the bristle assembly 120 is disposed on the mold body 110, the actual cavity surface is not defined solely by the cavity surface 112 of the mold body 110, but is jointly defined by the cavity surface 112 and the bristle assembly 120 disposed on the mold body 110. By constructing a recess 116 in the mold body 110, the desired cavity surface shape and cavity shape can be advantageously maintained even when the bristle assembly 120 is disposed on the mold body 110. It is understood that a recess 116 can be constructed to accommodate only one bristle assembly 120, but can also, for example, accommodate multiple bristle assemblies 120 that are adjacent to each other.

[0117] Naturally, as Figure 4 As shown, when the mold body 110 includes a magnet 114, the position of the recess 116 can correspond to the position of the magnet 114. Especially when the bristle assembly 120 is attached to the mold body 110 only magnetically, during demolding, the bristle assembly 120 may be pulled by the foamed product and laterally move or slide away from its original position on the cavity surface 112. The recess 116 constructed in the mold body 110 can form a lateral stop structure for the bristle assembly 120, thereby advantageously preventing the bristle assembly 120 from laterally moving along the cavity surface 112. Alternatively or additionally, the bristle assembly 120 can also be adhered to the mold body 110 by means of double-sided tape and / or adhesive to avoid such lateral movement. It is understood that in Figure 2 In the illustrated embodiment, such a recess 116 may also be provided to prevent the barb assembly 120 from moving and shifting on the cavity surface 112.

[0118] Figure 9 and Figure 10 The diagram illustrates a burr structure 127 of a burr assembly 120 according to some embodiments of this application. The burr structure 127 may, for example, have a generally Y-shaped, T-shaped, or C-shaped shape. Figure 9In the illustrated embodiment, the burr structure 127 may have a rod 131 extending from the base surface 130, the rod 131 being connected to the base surface 130 via a root 132. Here, the root 132 may smoothly connect the base surface 130 and the rod 131. At least one, preferably two, hooks 133 extending laterally from the top region of the rod 131 and curving towards the base surface 131 may extend from the top region of the rod 131. The burr structure 127 may primarily use the hooks 133 to hook the surface material of the foamed article, thereby retaining the surface material on the burr surface 121 of the burr assembly 120. As shown, the two hooks 133 may be arranged substantially symmetrically. Figure 10 The burr structure 127 shown on the left is... Figure 9 The burr structure 127 is generally similar, but the root 132 of the burr structure 127 can be constructed as a stepped shape. Furthermore, with... Figure 9 Compared to the burr structure 127 shown, the two hooks 133 can have a smaller lateral spacing here. Figure 10 The burr structure 127 shown in the middle can have a generally umbrella-shaped or mushroom-shaped form and therefore a relatively smooth top 134. Figure 10 The burr structure 127 shown on the right can have a substantially C-shaped shape, so that the “root” 132, “rod” 131 and “hook” 133 of the burr structure 127 can smoothly transition to each other starting from the base surface 130 (not shown).

[0119] Not limited to the shown burr structure 127, various other shapes of burr structure 127 are conceivable. However, within the scope of this application, on the one hand, the burr structure 127 should be able to reliably hook onto the surface material of the foamed article while not significantly damaging the fiber structure of the surface material when unhooking it; on the other hand, the burr structure 127 should extend a certain height from the base surface 131 so that the release agent used in the foaming process does not block or cover the hook portion 133 of the burr structure 127 too quickly (e.g., after only a few applications of the release agent), thus causing the burr assembly 120 to fail. A burr structure 127 height between 0.3 mm and 5 mm, particularly between 0.6 mm and 2.5 mm, has been proven to meet this requirement.

[0120] In this application, the foamed article 200 to be manufactured can be a foamed article 200 for use in seats, particularly vehicle seats 400. Figure 11A portion of the vehicle seat 400, such as the cushion area, is schematically shown in cross-sectional view. A foam article 200, serving as filling, can be mounted on the frame 410 of the vehicle seat 400. A seat cover 420 can at least partially cover the foam article 200 and the frame 410, defining the appearance of the vehicle seat 400. Here, the side of the foam article 200 facing the frame 410 can be referred to as the back side of the foam article 200. The foam article 200 may have a surface material 210 at least on its back side to improve the strength of the foam article 200 and / or prevent noise generated when the foam article 200 contacts and rubs against the frame 410. The surface material 210 is, in particular, a nonwoven fabric.

[0121] Figure 12 An exemplary illustration shows the surface material 210 in a laid-out state, where the area marked with a black square represents the functional area 211 of the surface material 210 for attachment to the bristle assembly 120. It should be noted that... Figure 12 The distribution of the functional areas 211 on the surface material 210 is marked with black squares only for clarity; however, such black squares do not actually exist in the surface material 210. Generally, one bristle assembly 120 can be attached to one functional area 211, but it is also conceivable that multiple closely spaced functional areas 211 form a larger area for attaching, for example, multiple bristle assemblies 120. It can be understood that the distribution and arrangement of the various functional areas 211 of the surface material 210 substantially corresponds to the distribution and arrangement of the various bristle assemblies 120 on the cavity surface 112 of the corresponding mold 100.

[0122] exist Figure 12 In this design, the first region 212 of the surface material 210, enclosed by a box, can be a relatively flat area of ​​the foamed article 200, while the second region 213 can be an area of ​​the foamed article 200 with a more complex surface shape and therefore lower flatness. The number of functional areas 211 in the first region 212 with higher flatness can be less than the number of functional areas 211 in the second region 213 with lower flatness. Correspondingly, the density of the bristle assembly 120 in the region of the cavity surface 112 of the mold 100 corresponding to the first region 212 can be less than the density of the bristle assembly 120 in the region of the cavity surface 112 of the mold 100 corresponding to the second region 213. By using more bristle assemblies 120, it is advantageous to ensure that the surface material 210 still adheres well to the cavity surface 112 in areas with more complex surface shapes or lower flatness.

[0123] The following is combined with Figure 13 and Figure 14An example of a method 300 for manufacturing a foamed article 200 according to this application is described. The various method steps of method 300, which will be described in detail below, can be performed manually and / or (e.g., by means of an industrial robot) automatically.

[0124] like Figure 13 As shown, the bristle assembly 120 can be first disposed on the mold body 110 in step a. Depending on the specific construction of the mold 100, the bristle assembly 120 can be fixed to the mold body 110, for example, magnetically and / or adhesively and / or mechanically. Specifically, the bristle assembly 120 can be magnetically adsorbed onto the cavity surface 112 of the mold 100, attached to the cavity surface 112 of the mold 100 by means of double-sided tape and / or adhesive, disposed on the cavity surface 112 of the mold 100 by means of a connector, and / or disposed on the cavity surface 112 of the mold 100 by means of a spring-loaded quick-change mechanism, etc.

[0125] Subsequently, in step b, the surface material 210 of the foamed article 200 can be attached to the bristle assembly 120, thereby holding the surface material 210 on the cavity surface 112 of the mold 100 by means of the bristle assembly 120. Specifically, the surface material 210 can be covered on the cavity surface 112 where the bristle assembly 120 is already provided, and then a force can be applied from the side of the surface material 210 away from the cavity surface 112 to at least the corresponding working area 211 of the surface material 210, so that the surface material 210 is attached to the bristle assembly 120 at least with its working area 211. The surface material used in step b can be a surface material that has undergone pretreatment, such as machining, sewing, welding, thermoforming, etc. Specifically, when the structure of the foamed product is simple, the surface material to be set on the surface of the mold cavity can be, for example, a 2D surface material, which can be formed by mechanical processing such as stamping; when the structure of the foamed product is relatively complex, the surface material to be set on the surface of the mold cavity can be a 3D surface material with a three-dimensional structure, which can be formed by stamping and then sewing or welding, or by hot pressing.

[0126] After the surface material of the foamed article is held on the cavity surface 112, foaming can be performed in step c. The foaming process can be carried out in a known manner and will not be described in detail here.

[0127] Subsequently, the foamed article can be removed from the mold 100 in step d. During this process, separation of the foamed article 200 from the bristle assembly 120 and / or separation of the bristle assembly 120 from the mold body 110 may occur. However, in a preferred embodiment, only the foamed article 200 is removed from the bristle assembly 120 in step d, while the bristle assembly 120 remains in the mold body 110. Even so, in actual production, some bristle assemblies 120 may still be unintentionally carried away from the mold body 110 by the foamed article 200. Therefore, before laying the new surface material 210 on the mold body 110, it can be checked whether all the bristle assemblies 120 have been properly positioned on the mold body 110. If necessary, missing bristle assemblies 120 can be added or their positions adjusted.

[0128] Furthermore, for example, at the end of the production of a batch of foamed products, the bristle assembly 120 can be removed from the mold body 110 in step e so that, for example, a new bristle assembly can be replaced for the production of the next batch of foamed products.

[0129] Figure 14 An exemplary flowchart is shown during mass production using method 300 according to this application. Here, after one manufacturing cycle is completed with mold 100, or one production cycle, the bristle assembly 120 can remain on the mold body 110 and continue to be used in the next manufacturing cycle. Figure 14 As shown, step a, i.e., setting the bristle assembly 120 on the mold body 110, can be completed in the preparatory work before starting the manufacturing cycle of steps b, c, and d. Then, mass production of the foamed article 200 can officially begin, where the manufacturing cycle can be repeatedly performed, i.e., repeatedly performing step b (holding the surface material of the foamed article on the bristle assembly), step c (foaming), and step d (removing the foamed article from the mold) sequentially. The actual number of times the manufacturing cycle is performed from the last implementation of step a can be counted as n. After N manufacturing cycles (i.e., when n ≥ N), the bristle assembly 120 can be removed from the mold body 110 in step e to, for example, replace with a new bristle assembly 120. The frequency of replacing the bristle assembly 120 can be controlled by a threshold N, which, for example, can be between 100 and 5000, for example, between 200 and 2000. Furthermore, the bristle assembly 120 can also be replaced, for example, after one or more batches or one or more shifts.

[0130] This application also relates to a foamed article 200, such as the foamed article for a vehicle seat 400 as described above. The foamed article 200 can be manufactured, in particular, by means of the mold 100 and / or the method 200 as described above. During the manufacturing process, the surface material of the foamed article 200 at least in its functional area 211 (see...) Figure 12 The bristle assembly 120 is attached to the mold 100. When the foamed article 200 is separated from the bristle assembly 120, the bristle structure 127 of the bristle assembly 120 may slightly elongate or pull the fibers of the surface material 210 from the surface of the surface material 210.

[0131] Figure 15 and Figure 16 The fiber distribution of the surface material 210 of the foamed article in the functional area is illustrated at different magnifications. The area circled in the figure substantially corresponds to the functional area of ​​the surface material. It can be seen that in the functional area, the fibers of the surface material 210 are pulled out from the surface of the surface material 210 by the burr structure 127. Therefore, in the functional area, the height by which the fibers of the surface material 210 extend beyond the surface of the surface material (which substantially corresponds to the equivalent surface of the compacted body of the surface material 210 fibers) is greater than in other areas. Alternatively, in the functional area, the average height of the outermost fibers of the surface material 210 can be greater than the average height of the outermost fibers of the surface material in other areas. In other words, in the functional area, the surface fiber density of the surface material can be lower than the surface fiber density in other areas; and / or in the functional area, the surface roughness of the surface material can be higher than the surface roughness in other areas. Furthermore, when separating the foamed product 200 from the bristle assembly 120, the bristle structure 127 of the bristle assembly 120 may slightly elongate the fibers of the surface material 210. Therefore, at least in the functional area 211 of the surface material 210, the average fiber length of the surface material 210 may be greater than the average fiber length in other areas.

[0132] In addition, for example, when using such Figure 2 and Figure 3 In the case of the bristle assembly 120 protruding from the cavity surface 112, the foamed article 200 produced may have a recess in the functional area 211 corresponding to the bristle assembly 120, the recess being caused by the bristle assembly 120, and thus the shape of the recess may substantially correspond to the shape of the bristle assembly 120.

[0133] In this application, by employing the bristle assembly 120 to secure the surface material 210, the use of disposable permanent magnet and / or ferromagnetic material sheets (e.g., iron powder sheets) can be advantageously reduced or even avoided. Advantageously, in the manufactured foamed article 200, at least in the functional area 211 of the surface material 210 for attachment to the bristle assembly 120, there are no permanent magnet and / or ferromagnetic material sheets (e.g., iron powder sheets) between the foamed material and the surface material. In some embodiments, the bristle assembly 120 can be used to replace most of the iron powder sheets, so that in the manufactured foamed article 200, the number of permanent magnet and / or ferromagnetic material sheets can be less than the number of functional areas 211. For example, iron powder sheets can be used only in the edge region of the surface material 210, preferably only in one edge region, while the bristle assembly 120 is used to secure the surface material 210 in other regions. For example, in such cases... Figure 12 In the surface material 210 shown, iron powder film can be used only in the upper edge area outlined by the dotted line. Particularly advantageously, a bristle assembly 120 can be used instead of all the iron powder film, thus eliminating the need for permanent magnet and / or ferromagnetic material sheets in the manufactured foamed article 200. Therefore, by omitting the permanent magnet and / or ferromagnetic material sheets, the manufacturing cost of the foamed article 200 itself can be reduced, thereby reducing the manufacturing cost of products including the foamed article 200, such as vehicle seat 400; furthermore, especially when the surface material 210 of the foamed article is visible to the user, this also contributes to the consistency and aesthetics of the final product's appearance.

[0134] Exemplary embodiments according to this application have been described above with reference to the accompanying drawings. However, those skilled in the art will understand that various changes and modifications can be made to the exemplary embodiments of this application without departing from the spirit and scope of this application. All changes and modifications are included within the scope of protection of this application as defined by the claims. This application is defined by the appended claims, and equivalents of those claims are also included.

Claims

1. A mold for manufacturing foamed products, characterized in that, The mold (100) includes a mold body (110) and a bristle assembly (120) detachably disposed on the mold body. When the bristle assembly is connected to the mold body, the front of the bristle assembly opposite to the mold body includes a bristle surface (121). The bristle assembly is configured to detachably hold the surface material (210) of the foamed article (200) on the mold body by means of the bristle surface.

2. The mold according to claim 1, characterized in that, The barb assembly is mounted on the mold body in a magnetic and / or adhesive and / or mechanical manner.

3. The mold according to claim 1, characterized in that, The barb assembly is disposed on the cavity surface (112) of the mold in a magnetic and / or adhesive and / or mechanical manner.

4. The mold according to any one of claims 1 to 3, characterized in that, The burr assembly includes a burr (123) with the burr surface and a magnetic element (122) fixed to the burr. The mold body includes a magnet (114), and the magnetic element and the magnet are magnetically attracted to each other.

5. The mold according to claim 4, characterized in that, The barb assembly includes a back substrate (124), with the barbs, magnetic components, and back substrate stacked sequentially.

6. The mold according to claim 5, characterized in that, The bristles, magnetic components, and back substrate are bonded together.

7. The mold according to claim 5 or 6, characterized in that, The bristles are connected to the back substrate and the magnetic element is clamped between the bristles and the back substrate.

8. The mold according to claim 7, characterized in that, The bristles are connected to the back substrate in a form-locking, force-locking, and / or material-locking manner.

9. The mold according to claim 8, characterized in that, The bristle blades are ultrasonically welded to the back substrate.

10. The mold according to claim 5 or 6, characterized in that, The bristle and / or the magnetic element and / or the back substrate are respectively constructed as sheets.

11. The mold according to claim 5 or 6, characterized in that, The bristles and the back substrate extend at least partially beyond the edge of the magnetic element, and the bristles and the back substrate are directly connected to each other in the region (125) extending beyond the edge of the magnetic element.

12. The mold according to claim 11, characterized in that, The barbs and the back substrate completely cover the magnetic element and extend beyond the magnetic element over its entire outer periphery.

13. The mold according to claim 4, characterized in that, The magnetic components include permanent magnet materials and / or ferromagnetic materials.

14. The mold according to claim 13, characterized in that, The magnetic component is constructed of a permanent magnet material sheet and / or a ferromagnetic material sheet.

15. The mold according to claim 13, characterized in that, The magnetic component is constructed as a sheet made of permanent magnet material powder and / or ferromagnetic material powder and rubber, and the sheet is flexible and bendable.

16. The mold according to claim 5 or 6, characterized in that, The bristles and / or the back substrate are made of nylon or polypropylene.

17. The mold according to any one of claims 1 to 3, characterized in that, The bristle assembly can be attached to the mold body using double-sided tape and / or adhesive.

18. The mold according to claim 17, characterized in that, The double-sided tape and / or adhesive are heat-resistant.

19. The mold according to any one of claims 1 to 3, characterized in that, The bristle assembly is connected to the mold body by means of a connector, the mold body including a mating portion for the connector.

20. The mold according to claim 19, characterized in that, The connector includes an external thread, and the mating portion includes an internal thread for engaging with the external thread; and / or the connector includes a locking portion, and the mating portion includes a locking portion for engaging the locking portion.

21. The mold according to claim 19, characterized in that, The connector and the barb assembly are constructed as a single piece.

22. The mold according to claim 21, characterized in that, The connector is injection molded, welded, or bonded to the bristle assembly.

23. The mold according to claim 19, characterized in that, The connector and the bristle assembly are constructed independently of each other.

24. The mold according to claim 23, characterized in that, The connector is constructed as a bolt.

25. The mold according to any one of claims 1 to 3, characterized in that, The mold includes a spring-loaded quick-change mechanism for the barb assembly.

26. The mold according to any one of claims 1 to 3, characterized in that, The bristle assembly has a circular, polygonal, or irregular shape; and / or the maximum extension dimension of the bristle assembly is 5 mm to 100 mm; and / or the thickness of the bristle assembly is 0.5 mm to 6 mm.

27. The mold according to any one of claims 1 to 3, characterized in that, A recess (116) is constructed in the mold body that is recessed relative to the cavity surface of the mold, the recess being constructed to accommodate the barb assembly.

28. The mold according to claim 27, characterized in that, The recess has a shape corresponding to the bristle assembly; and / or the depth of the recess is adapted to the thickness of the bristle assembly, such that when the bristle assembly is housed in the recess, the burr surface of the front of the bristle assembly is slightly higher than the cavity surface of the mold.

29. The mold according to any one of claims 1 to 3, characterized in that, The mold includes multiple barb assemblies, which are distributed at intervals on the cavity surface of the mold.

30. The mold according to any one of claims 1 to 3, characterized in that, The density of the bristle assembly in the first region of the mold cavity surface is less than the density of the bristle assembly in the second region of the mold cavity surface, and the flatness of the first region is greater than the flatness of the second region.

31. The mold according to any one of claims 1 to 3, characterized in that, The foamed product is a foamed product for use in seats; and / or the surface material is a non-woven fabric.

32. The mold according to any one of claims 1 to 3, characterized in that, The force between the burr surface and the surface material is less than the force between the burr assembly and the mold body.

33. A method for manufacturing foamed products, characterized in that, The foamed article (200) is manufactured using the mold (100) according to any one of claims 1 to 32.

34. The method according to claim 33, characterized in that, The method includes at least one of the following steps: a. The barb assembly (120) is mounted on the mold body (110); b. Hold the surface material (210) of the foamed product (200) on the bristle assembly; c. Foaming molding; d. Remove the foamed product from the mold.

35. The method according to claim 34, characterized in that, During the process of removing the foamed product from the mold, the bristle assembly remains on the mold body.

36. The method according to claim 34 or 35, characterized in that, Step a includes: setting the barb assembly onto the mold body magnetically and / or adhesively and / or mechanically.

37. The method according to claim 36, characterized in that, Step a includes at least one of the following steps: The barb assembly is magnetically adsorbed onto the cavity surface (112) of the mold; The barb assembly is attached to the cavity surface of the mold using double-sided tape and / or adhesive. The burr assembly is set on the cavity surface of the mold using a connector; The barb assembly is set on the cavity surface of the mold by means of a spring-loaded quick-change mechanism.

38. The method according to claim 34 or 35, characterized in that, Step a is performed before step b, and step b includes: A force is applied from at least one side of the surface material away from the cavity surface to the functional area (211) of the surface material for attachment to the bristle assembly, such that at least said functional area of ​​the surface material is attached to the bristle assembly, thereby setting the surface material on the cavity surface of the mold.

39. The method according to claim 34 or 35, characterized in that, The surface material used in step b is a pre-treated surface material, and the pre-treatment includes at least one of machining, sewing, welding, and hot pressing.

40. The method according to claim 34 or 35, characterized in that, Step d refers to separating the foamed product from the bristle assembly.

41. The method according to claim 34 or 35, characterized in that, The method further includes step e: removing the barb assembly from the mold body.

42. The method according to claim 41, characterized in that, A manufacturing cycle includes at least steps b, c, and d, with step e performed only once after a certain number of manufacturing cycles, the number of which is between 100 and 5000.

43. The method according to claim 34 or 35, characterized in that, At least one step of the method is performed manually and / or automatically.

44. A foamed product, characterized in that, The foamed article is a foamed article for use in a seat and as a filling material in the seat. The foamed article includes a surface material and a foaming material. The surface material has an active area for attachment to a bristle assembly. The active area is located on the side of the surface material opposite to the foaming material. The surface material of the foamed article can be attached to the bristle assembly of the mold at least with respect to the active area.

45. The foamed article according to claim 44, characterized in that, In the functional area, the height by which the fibers of the surface material extend beyond the surface of the surface material is greater than the height by which the fibers of the surface material extend beyond the surface of the surface material in other areas. And / or in the region of action, the average fiber length of the surface material is greater than the average fiber length in other regions; And / or in the area of ​​action, the surface fiber density of the surface material is lower than that in other areas.

46. ​​The foamed article according to claim 44 or 45, characterized in that, The surface material of the foamed product has a recess in the functional area, the shape of which substantially corresponds to the shape of the bristle assembly.

47. The foamed article according to claim 44 or 45, characterized in that, At least in the functional area, there are no permanent magnet sheets and / or ferromagnetic sheets between the foaming material and the surface material of the foamed article.

48. The foamed article according to claim 44 or 45, characterized in that, In the foamed product, the number of permanent magnet material sheets and / or ferromagnetic material sheets is less than the number of the functional areas.

49. The foamed article according to claim 48, characterized in that, There are no permanent magnet material sheets and / or ferromagnetic material sheets in the foamed product.

50. The foamed article according to claim 44 or 45, characterized in that, The foamed article is manufactured by means of a mold according to any one of claims 1 to 32, and / or the foamed article is manufactured by means of a method according to any one of claims 33 to 43.

51. The foamed article according to claim 44 or 45, characterized in that, The surface material is non-woven fabric.

52. The foamed article according to claim 51, characterized in that, The foamed article is a foamed article for vehicle seats, and the surface material is located at least on the back side of the foamed article.

53. A vehicle seat, characterized in that, The vehicle seat comprises a foamed article according to any one of claims 44 to 52.

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