Seat back plate, seat, vehicle and manufacturing method of seat back plate

Abstract

The invention discloses a seat back plate, a seat, a vehicle and a manufacturing method of the seat back plate, and the manufacturing method of the seat back plate comprises the following steps: coating a flexible material in a first half mold to obtain a first coating; coating a foaming material in the first half mold and coating the first coating to obtain a composite layer; wherein the composite layer comprises the first coating and a second coating formed by the foaming material; a backboard framework is placed in the first half mold and placed on the composite layer; and a second half mold and the first half mold are assembled and cured, so that the first coating forms a surface layer, the second coating forms a foaming layer, and the seat back plate is obtained. The seat back plate provided by the embodiment of the invention has the advantages of high manufacturing efficiency, low VOC value and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile accessories, and in particular to a seat back plate, a seat, a vehicle and a method for manufacturing the seat back plate. Background Art

[0002] The seat back of a vehicle usually includes a backboard frame, a foaming layer and a surface layer. In the related art, in the process of manufacturing the seat back, it is necessary to first form a foaming layer through a foaming process, then manually coat the foaming layer on the backboard frame, and then manually coat the surface layer on the seat backboard frame coated with the foaming layer. The above-mentioned method for manufacturing the seat back requires separately manufacturing the foaming layer and the surface layer, and then connecting the surface layer, the foaming layer and the backboard frame by bonding, which results in a relatively long manufacturing time for the seat back, that is, the manufacturing efficiency of the seat back is low. Summary of the invention

[0003] The present invention aims to solve one of the technical problems in the related art at least to a certain extent.

[0004] To this end, an embodiment of the present invention provides a method for manufacturing a seat back plate to improve the manufacturing efficiency of the seat back plate.

[0005] The method for manufacturing the seat back plate of the embodiment of the present invention comprises the following steps:

[0006] Applying a flexible material to the first half mold to obtain a first coating;

[0007] Applying a foaming material in the first half mold and on the first coating layer to obtain a composite layer; wherein the composite layer includes the first coating layer and a second coating layer formed by the foaming material;

[0008] Place the backboard frame into the first half mold and place it on the composite layer;

[0009] The second half mold is molded together with the first half mold and cured so that the first coating layer forms a surface layer and the second coating layer forms a foaming layer, thereby obtaining the seat back panel.

[0010] In some embodiments, before the foaming material is coated on the first half mold and after the foaming material is coated in the first half mold, the temperature of the first half mold is 62° C. to 68° C.

[0011] In some embodiments, the flexible material is sprayed into the first half mold using a spray gun with a pressure of 65Pa to 70Pa; and / or, the foaming material is sprayed onto the first coating layer using a spray gun with a pressure of 65Pa to 70Pa.

[0012] In some embodiments, the material of the backplane skeleton includes polypropylene and glass fiber; the flexible material and the foaming material are both polyurethane.

[0013] In some embodiments, the thickness of the backboard skeleton is 2.5 mm to 3 mm; the sum of the thickness of the surface layer and the thickness of the foaming layer is 4 mm to 4.5 mm.

[0014] In some embodiments, the thickness of the surface layer is 0.5 mm to 1 mm; the thickness of the foaming layer is 3 mm to 3.5 mm.

[0015] In some embodiments, a texture is provided in the first half mold so that a surface of the skin layer facing away from the foaming layer is textured; and / or a pattern is provided in the first half mold so that a pattern is formed on the surface of the skin layer facing away from the foaming layer.

[0016] An embodiment of the present invention further provides a seat back panel.

[0017] The seat back panel of the embodiment of the present invention is manufactured by the manufacturing method described in any of the above embodiments.

[0018] An embodiment of the present invention further provides a seat.

[0019] The seat of the embodiment of the present invention comprises the seat backboard described in any one of the above embodiments.

[0020] An embodiment of the present invention also provides a vehicle.

[0021] The vehicle according to the embodiment of the present invention comprises the seat described in any one of the above embodiments.

[0022] The method for making a seat back in an embodiment of the present invention is to coat a flexible material and a foaming material in a first half mold in sequence to form a composite layer, then place a backboard frame in the first half mold and place it on the composite layer, and finally close the second half mold and the first half mold and cure to obtain a seat back. The surface layer and the foaming layer of the seat back are respectively obtained by curing a first coating layer formed by a first flexible material and a second coating layer formed by a foaming material. During the curing process, at least the foaming material has viscosity, and the viscosity of the foaming material is used to achieve the connection between the foaming layer and the surface layer and between the foaming layer and the backboard frame. Therefore, compared with the method for making a seat back in the related art, the process of separately making the foaming layer and the surface layer, as well as the process of bonding the surface layer, the foaming layer and the backboard frame can be omitted, thereby shortening the production time of the seat back and improving the production efficiency of the seat back. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a schematic structural diagram of a seat back plate according to an embodiment of the present invention.

[0024] Figure 2 yes Figure 1 Exploded view of the center seat back panel.

[0025] Figure 3 It is a flow chart of a method for manufacturing a seat back panel according to an embodiment of the present invention.

[0026] Figure 4 The present invention is a state diagram of spraying a flexible material into a first half mold in a method for manufacturing a seat back panel according to an embodiment of the present invention.

[0027] Figure 5 This is a state diagram of spraying foam material into a first half mold in a method for manufacturing a seat back panel according to an embodiment of the present invention.

[0028] Figure 6 The present invention is a state diagram of a second half mold and a first half mold after the mold is closed in a method for manufacturing a seat back panel according to an embodiment of the present invention.

[0029] Figure 7 This is a state diagram of a seat back plate when it is taken out in a method for manufacturing a seat back plate according to an embodiment of the present invention.

[0030] Reference numerals:

[0031] 100. Seat back panel;

[0032] 1. Backboard frame;

[0033] 2. Foaming layer;

[0034] 3. Surface layer;

[0035] 4. First coating;

[0036] 5. Composite layer.

[0037] 10. first half mold; 101. cavity;

[0038] 20. The second half of the mold. DETAILED DESCRIPTION

[0039] Embodiments of the present invention are described in detail below, and examples of the embodiments are shown in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to be used to explain the present invention, but should not be understood as limiting the present invention.

[0040] like Figure 1 and Figure 2 As shown, the seat back plate 100 of the embodiment of the present invention comprises a back plate frame 1, a foam layer 2 and a surface layer 3 which are arranged in sequence. Figure 3 As shown, the manufacturing method of the seat back plate 100 of the embodiment of the present invention comprises the following steps:

[0041] S1, apply the flexible material to the first half mold 10 to obtain the first coating 4 (such as Figure 4 shown);

[0042] S2, coating the foaming material in the first half mold 10 and on the first coating layer 4 to obtain a composite layer 5; wherein the composite layer 5 includes the first coating layer 4 and a second coating layer (such as Figure 5 shown);

[0043] S3, placing the backboard frame 1 into the first half mold 10 and placing it on the composite layer 5;

[0044] S4, the second half mold 20 and the first half mold 10 are molded together (such as Figure 6 As shown) and matured so that the first coating 4 forms a surface layer 3 and the second coating forms a foaming layer 2.

[0045] The method for manufacturing the seat back 100 of the embodiment of the present invention is to coat the flexible material and the foaming material in the first half mold 10 in sequence to form a composite layer 5, then put the backboard frame 1 into the first half mold 10 and place it on the composite layer 5, and finally close the second half mold 20 and the first half mold 10 and ripen, thereby obtaining the seat back 100. Among them, the surface layer 3 and the foaming layer 2 of the seat back 100 are respectively obtained by ripening the first coating layer 4 formed by the first flexible material and the second coating layer formed by the foaming material. During the ripening process, at least the foaming material has viscosity, and the viscosity of the foaming material is used to achieve the connection between the foaming layer 2 and the surface layer 3 and between the foaming layer 2 and the backboard frame 1.

[0046] Therefore, compared with the manufacturing method of the seat back panel in the related art, the process of separately manufacturing the foam layer and the surface layer, as well as the process of bonding the surface layer, the foam layer and the back panel frame can be omitted, thereby shortening the manufacturing time of the seat back panel 100 and improving the manufacturing efficiency of the seat back panel 100.

[0047] In addition, in the related art, the surface layer, the foaming layer and the backboard frame are connected by bonding. Since the adhesive contains a large amount of volatile organic compounds (VOC), the manufactured seat backboard contains a large amount of volatile organic compounds, which is harmful to human health. The manufacturing method of the seat backboard 100 of the embodiment of the present invention utilizes the viscosity of the foaming material during the maturation process to achieve the connection between the foaming layer 2 and the surface layer 3 and between the foaming layer 2 and the backboard frame 1. Therefore, the use of adhesives can be avoided, thereby reducing the VOC value.

[0048] Therefore, the seat back panel 100 according to the embodiment of the present invention has the advantages of high manufacturing efficiency and low VOC value.

[0049] After aging, cool for one hour and then open the mold, that is, remove the second half mold 20 from the first half mold 10, and Figure 7 The seat back panel 100 is taken out (demolded) from the first half mold 10 in the direction of the arrow in FIG.

[0050] In some embodiments, the release agent is first applied to the first mold half 10 before the flexible material is applied to the first mold half 10. In other words, the release agent is first applied to the first mold half 10, and then the flexible material is applied to the first mold half 10 and onto the release agent.

[0051] For example, the release agent is first coated in the first half mold 10 , and then the flexible material is coated in the first half mold 10 and on the release agent.

[0052] By first applying the release agent to the first half mold 10 and then applying the release agent to the flexible material, the flexible material and the first half mold 10 are separated by the release agent, so that the seat back panel 100 can be easily demolded and removed from the first half mold 10 .

[0053] In some embodiments, before the foaming material is coated on the first half mold 10 and after the foaming material is coated inside the first half mold 10 , the temperature of the first half mold 10 is 62° C. to 68° C.

[0054] For example, the first half mold 10 is first heated to a temperature of 62° C. to 68° C.; then, a release agent is applied to the first half mold 10; then, a flexible material is applied to the first half mold 10 and to the release agent (e.g., Figure 4 Afterwards, the foaming material is coated in the first half mold 10 and coated on the first coating 4 formed by the flexible material (as shown in Figure 5 During the above process, the temperature of the first half mold 10 is maintained at 62°C to 68°C.

[0055] Therefore, it can be ensured that the foaming material is fully foamed when coated in the first half mold, which is beneficial to improving the quality of the seat back panel 100.

[0056] Optionally, the flexible material is sprayed into the first half mold 10 using a spray gun, and the pressure of the spray gun is 65Pa-70Pa.

[0057] Using a spray gun to spray the flexible material into the first half mold 10 is not only beneficial to improving the spraying effect of the flexible material and further improving the production efficiency of the seat back 100; it is also beneficial to improving the coating uniformity of the flexible material in the first half mold 10 and improving the quality of the seat back 100.

[0058] Of course, in other embodiments, the flexible material may also be sprayed into the first half mold 10 manually.

[0059] Optionally, the foaming material is sprayed onto the first coating layer 4 using a spray gun, and the pressure of the spray gun is 65Pa-70Pa.

[0060] Using a spray gun to spray the foam material into the first half mold 10 is not only beneficial to improving the spraying effect of the foam material and further improving the production efficiency of the seat back 100; it is also beneficial to improving the coating uniformity of the foam material in the first half mold 10 and improving the quality of the seat back 100.

[0061] Of course, in other embodiments, the foaming material may also be sprayed into the first half mold 10 manually.

[0062] Optionally, the material of the backboard frame 1 includes polypropylene (PP) and glass fiber (GF), and the flexible material and the foaming material are both polyurethane.

[0063] For example, the backboard frame 1 is PP+20% GF, the flexible material is polyurethane, and the foaming material is hard polyurethane foam.

[0064] In the related art, the material of the backboard frame is usually ABS, which has a relatively high cost.

[0065] The material of the backboard frame 1 includes polypropylene and glass fiber. Compared with the backboard frame using ABS, the overall strength of the seat backboard 100 can be guaranteed while reducing the cost of the seat backboard 100. In addition, the flexible material uses polyurethane, so that the flexible material also has viscosity during the aging process, and the viscosity of the flexible material is used to achieve the connection between the foaming layer 2 and the surface layer 3, thereby improving the connection reliability of the foaming layer 2 and the surface layer 3.

[0066] Optionally, the thickness of the backboard skeleton 1 is 2.5 mm to 3 mm, and the sum of the thickness of the surface layer 3 and the thickness of the foaming layer 2 is 4 mm to 4.5 mm.

[0067] For example, the thickness of the backboard skeleton 1 is 2.5 mm, and the sum of the thickness of the surface layer 3 and the thickness of the foaming layer 2 is 4 mm.

[0068] By setting the thickness of the backboard frame 1 to 2.5mm~3mm and the sum of the thickness of the surface layer 3 and the thickness of the foam layer 2 to 4mm~4.5mm, while ensuring that the seat backboard 100 has sufficient strength and low cost, it is beneficial to improve the softness of the seat backboard 100, thereby helping to improve the touch of the seat backboard 100 and improve the user experience.

[0069] Optionally, the thickness of the surface layer 3 is 0.5 mm to 1 mm, and the thickness of the foaming layer 2 is 3 mm to 3.5 mm.

[0070] For example, the thickness of the surface layer 3 is 0.5 mm, and the thickness of the foam layer 2 is 3.5 mm.

[0071] By setting the thickness of the surface layer 3 to 0.5 mm to 1 mm and the thickness of the foam layer 2 to 3 mm to 3.5 mm, the cost of the seat back 100 can be reduced while ensuring high flexibility of the seat back 100 .

[0072] Optionally, a texture is provided in the first half mold 10 so that a surface of the skin layer 3 facing away from the foaming layer 2 is textured.

[0073] For example, for example, Figure 7 As shown, the first half mold 10 has a cavity 101, and the cavity wall of the cavity 101 is provided with a texture. During the curing process, the surface of the surface layer 3 that is in contact with the cavity 101 forms a texture.

[0074] This helps to improve the aesthetic appearance of the seat back 100.

[0075] Optionally, a pattern is provided in the first half mold 10 so that a pattern is formed on the surface of the skin layer 3 facing away from the foaming layer 2 .

[0076] For example, Figure 7 As shown, the first half mold 10 has a cavity 101, and the cavity wall of the cavity 101 is provided with a pattern. During the curing process, the surface of the surface layer 3 that is in contact with the cavity 101 forms a pattern. In addition, although the surface layer in the related art is provided with a texture, since the surface layer is connected to the seat frame by bonding, the problem of the wrong direction of the texture is easy to occur. The method for manufacturing the seat back panel 100 of the embodiment of the present invention can effectively avoid the occurrence of the above problem.

[0077] This helps to improve the aesthetic appearance of the seat back 100.

[0078] Reference below Figures 4 to 7 The manufacturing method of the seat back plate 100 according to the embodiment of the present invention is described as follows:

[0079] First, a release agent is sprayed in the cavity 101 of the textured first half mold 10 to facilitate demolding of the seat back panel 100 after molding; after spraying the release agent, the flexible material can be sprayed immediately to obtain a first coating 4 (such as Figure 4 After spraying the flexible material, the foaming material can be sprayed immediately to obtain a composite layer 5 (as shown); Figure 5 As shown), during the whole process, the temperature of the first half mold 10 is set to 65±3°C; then, the backboard frame 3 is placed in the first half mold 10, and the second half mold 20 is combined with the first half mold 10 for integration, so as to obtain the seat backboard 100 (as shown in FIG. Figure 6 Finally, the mold is opened and the molded seat back panel 100 is removed from the first half mold 10 (as shown in FIG. Figure 7 shown).

[0080] The manufacturing method of the seat back panel 100 of the embodiment of the present invention can complete the entire process by a robot, without the need for manual operations such as back panel edging / trimming, thus saving surface materials. The manufacturing process can shorten the single-piece manufacturing time by more than half compared to the manufacturing process of the seat back panel in the related art.

[0081] For the convenience of description, the seat back panel in the related art where the foam layer and the surface layer are manually coated on the seat frame is referred to as a coated back panel, and the seat back panel 100 of the embodiment of the present invention is referred to as a sprayed back panel. Compared with the coated back panel, the sprayed back panel has the following advantages:

[0082] In terms of cost, the seat frame of the covered backboard is made of ABS material, and the foam layer and the surface layer are covered on the seat frame by manual coating. The material and labor costs make the cost of the covered backboard higher; the sprayed backboard uses PP+20% GF material, and the cost can be reduced by more than 10% compared with the covered backboard. In addition, the organic volatiles released by the sprayed backboard are much lower than those of the covered backboard, which greatly reduces the amount of glue used, VOC and odor problems. The sprayed backboard is a more environmentally friendly seat backboard.

[0083] In terms of appearance refinement, the color and texture of the surface layer 3 of the spray-coated backplane can be flexible and varied, and special colors can be customized after mass production, achieving maximum freedom in color and texture design; patterns and textures can be reflected on the mold according to special requirements, the gloss can be low, and sharp angles can be designed; the final product has good consistency, and there will be no problems such as incorrect texture direction, non-fitting coating, floating and local peeling.

[0084] In terms of touch, the covered back panel is covered with a foam layer, which feels similar to skin to the touch, but feels hard when pressed; while the sprayed back panel has a sense of contour, and the soft touch is more obvious when pressed, and it has sufficient cushioning. In actual comparison, the sprayed back panel feels far better than the covered back panel.

[0085] The seat according to the embodiment of the present invention comprises the seat back panel 100 according to any one of the above embodiments.

[0086] Since the seat back panel 100 has the advantages of high manufacturing efficiency and low VOC value, the seat according to the embodiment of the present invention has the advantages of high manufacturing efficiency and low VOC value.

[0087] The vehicle according to the embodiment of the present invention comprises the seat according to any one of the above embodiments.

[0088] Since the seat according to the embodiment of the present invention has the advantages of high manufacturing efficiency and low VOC value, the vehicle according to the embodiment of the present invention has the advantages of good riding comfort, etc.

[0089] Although the embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are illustrative and are not to be construed as limitations on the present invention. Changes, modifications, substitutions and variations of the above embodiments by those of ordinary skill in the art are all within the scope of protection of the present invention.

Claims

1. A method for manufacturing a seat back panel, characterized in that: The following steps are involved: Applying a flexible material to the first half mold to obtain a first coating; Applying a foaming material in the first half mold and on the first coating layer to obtain a composite layer; wherein the composite layer includes the first coating layer and a second coating layer formed by the foaming material; Place the backboard frame into the first half mold and place it on the composite layer; The second half mold is molded together with the first half mold and cured so that the first coating layer forms a surface layer and the second coating layer forms a foaming layer, thereby obtaining the seat back panel.

2. The method for manufacturing a seat back panel according to claim 1, characterized in that: Before the foaming material is coated on the first half mold and after the foaming material is coated in the first half mold, the temperature of the first half mold is 62° C. to 68° C.

3. The method for manufacturing a seat back panel according to claim 1, characterized in that: Spraying the flexible material into the first half mold using a spray gun, wherein the pressure of the spray gun is 65Pa to 70Pa; and / or The foaming material is sprayed on the first coating layer by using a spray gun, and the pressure of the spray gun is 65Pa-70Pa.

4. The method for manufacturing a seat back panel according to claim 1, characterized in that: The material of the backboard frame includes polypropylene and glass fiber; The flexible material and the foaming material are both polyurethane.

5. The method for manufacturing a seat back panel according to claim 4, characterized in that: The thickness of the backboard frame is 2.5 mm to 3 mm; The sum of the thickness of the surface layer and the thickness of the foaming layer is 4 mm to 4.5 mm.

6. The method for manufacturing a seat back panel according to claim 5, characterized in that: The thickness of the surface layer is 0.5 mm to 1 mm; The thickness of the foaming layer is 3 mm to 3.5 mm.

7. The method for manufacturing a seat back panel according to any one of claims 1 to 6, characterized in that: The first half mold is provided with a texture so that the surface of the surface layer facing away from the foaming layer is textured; and / or A pattern is arranged in the first half mold so that a pattern is formed on the surface of the skin layer facing away from the foaming layer.

8. A seat back panel, characterized in that: The method is prepared according to any one of claims 1 to 7.

9. A seat, characterized in that: The invention comprises the seat back panel as claimed in claim 8.

10. A vehicle, characterized in that: Including the seat described in claim 9.

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