High-strength light waist protection cushion and preparation method thereof
By using the same EPS foaming material to prepare a high-density outer coating material and a high-foaming ratio inner liner with a gradient density structure, the problem of poor overall integrity of the seat product was solved, and the structural stability and flexibility of the seat were improved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- ZUODIAN IND (HUBEI) CO LTD
- Filing Date
- 2024-11-16
- Publication Date
- 2026-05-19
AI Technical Summary
Existing seat products suffer from poor overall integrity due to the use of different materials, making them prone to breakage, affecting their service life and stress characteristics, and making it difficult to achieve optimal mechanical properties.
The upper and lower outer coating materials are made of the same EPS foam material as the inner liner, with a higher density than the inner liner. The high-density outer coating material is prepared by casting or spraying, while the inner liner is made of EPS material with a high foaming ratio, forming an overall structure with a gradient density.
Improve the structural stability and integrity of seating products, evenly distribute stress, enhance flexibility and comfort, extend service life, and strengthen product competitiveness.
Smart Images
Figure CN122056474A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of lumbar support cushion technology, specifically to a high-strength lightweight lumbar support cushion and its preparation method. Background Technology
[0002] An ergonomic chair is a chair designed to support the body's natural posture and reduce physical fatigue from prolonged sitting. Its design philosophy stems from in-depth research into human physiology and work habits, aiming to improve work efficiency and comfort while preventing health problems caused by poor posture over long periods. To address the discomfort and health issues associated with prolonged sitting, ergonomic chairs were developed. Advances in materials science and manufacturing processes have made the design and production of ergonomic chairs possible, resulting in more scientific and human-centered designs. The design features of ergonomic chairs include, but are not limited to, the following: First, the chair design supports the back, waist, and hips, reducing pressure points and providing even support; second, the human body... Ergonomic chairs typically feature multiple adjustment functions, such as height, seat depth, and backrest angle, to accommodate different user body sizes and preferences. Furthermore, they utilize breathable and soft materials, such as mesh or high-density foam, to provide a comfortable seating experience. Finally, by promoting correct posture, they reduce pressure on the spine and neck, lowering the risk of back and neck pain. In terms of materials and craftsmanship, modern ergonomic chairs primarily use environmentally friendly materials, such as recyclable plastics, metals, and wood. The manufacturing process incorporates the latest advancements in ergonomic research, combined with modern manufacturing techniques, to ensure the chair's precision and functionality. The application of these technologies not only improves production efficiency but also makes the chair design more ergonomic. Chinese Patent Publication No. CN113679204A discloses a posture-correcting cushion and its preparation method, wherein the posture-correcting cushion includes: a surface sheet that can be stretched to have a cavity; and a bonding film that is bonded to the inner wall of the cavity. A pad is bonded and fixed to a portion of the bonding membrane; a foamed material layer is filled by foaming to fill the unfilled cavity between the pad and the remaining portion of the bonding membrane, making the overall structure more integrated and the connection between the layers stronger; Chinese Patent Publication No. CN106827340B discloses a molded seat cushion, including an upper outer covering material, a lower outer covering material, and an inner liner made of honeycomb cotton located between the two. The edges of the upper and lower outer covering materials are connected to each other to form the edge of the seat cushion. The inner liner is a molded three-dimensional structure. The middle parts of the upper and lower outer covering materials are connected to the top and bottom surfaces of the inner liner, respectively. The concave and convex three-dimensional structure of the seat cushion is reflected by the concave and convex three-dimensional structure on the outer covering material and the inner liner. During preparation, the mold molds the outer covering material and honeycomb cotton in one step to obtain the seat cushion. It can also be used for printing. It not only has high preparation efficiency, low production cost, strong bonding, and good environmental protection, but also has the advantages of high elasticity and resilience, strong three-dimensionality, good support, and good aesthetics; However, the use of different materials in the above technology leads to poor overall integrity of the seat. When the seat is subjected to stress and deformation, the contact surfaces of different materials are prone to breakage. This not only seriously shortens the service life of the seat product, but also affects the stress characteristics of the seat product, making it difficult for the seat product to achieve the best mechanical state. To address the aforementioned problems, this invention proposes a high-strength, lightweight lumbar support cushion and its preparation method. Summary of the Invention
[0003] (1) Technical problems to be solved The purpose of this invention is to develop a seat product with excellent mechanical properties. To this end, this invention provides a high-strength, lightweight lumbar support seat cushion and its preparation method.
[0004] (2) Technical solution To achieve the objectives of this invention, the technical solution adopted is as follows: The present invention first provides a high-strength lightweight lumbar support cushion, including an upper outer covering material, a lower outer covering material, and an inner liner connected between the two. The upper outer covering material and the lower outer covering material are integrally formed so that the upper outer covering material and the lower outer covering material form a receiving space for filling the inner liner. The density of the upper outer covering material and the lower outer covering material is greater than that of the inner liner, and the upper outer covering material, the lower outer covering material and the inner liner are made of the same material.
[0005] Furthermore, both the upper and lower outer surface covering materials are made of EPS foam material, and the foaming ratio of the raw materials of the upper and lower outer surface covering materials is lower than that of the inner liner.
[0006] Furthermore, the edges of the upper and lower outer covering materials are connected to form the outer edge of the seat cushion.
[0007] Furthermore, the upper outer covering material has multiple first ventilation holes in its middle section, and the lower outer covering material has corresponding second ventilation holes in its middle section corresponding to the first ventilation holes. The edges of adjacent first and second ventilation holes are connected to form the inner edge of the seat cushion.
[0008] This invention also provides a method for preparing a high-strength, lightweight lumbar support cushion, comprising the following steps: Step 1: Add EPS resin and foaming agent of different mass ratios to two sets of pre-foaming equipment. By controlling the steam pressure, temperature, residence time and stirring rate in the two sets of foaming equipment, raw materials with low foaming ratio and raw materials with high foaming ratio can be prepared for later use. Step 2: After the upper mold and the lower mold are closed, a covering material cavity is formed. A layer of upper and lower surface covering material made of raw materials with low foaming ratio is bonded and formed on the inner wall of the covering material cavity. Step 3: After injecting high-expansion raw material into the space between the upper and lower outer covering materials and continuing to cool, a filling liner is formed. The high-expansion raw material and the incompletely solidified low-expansion raw material adhere to each other to form the bonding interface between the upper and lower outer covering materials and the filling liner, thus forming the lumbar support cushion body. Step 4: After the upper and lower molds are separated, remove the formed lumbar support cushion body and cool it to room temperature a second time.
[0009] Furthermore, the bonding molding method in step two includes, but is not limited to, either casting molding or spray molding.
[0010] Furthermore, in step two, the molding temperature is controlled between 85℃ and 100℃, and the molding time is controlled between seconds. Furthermore, the molding temperature in step three is controlled between 45℃ and 70℃ until the upper outer covering material, the lower outer covering material, and the inner filling liner reach the same temperature. Beneficial effects
[0011] This invention prepares a high-density outer coating material from high-density raw materials through casting or spraying. The process is simple and efficient. The exoskeleton structure formed by the outer coating material can ensure the appearance integrity of the seat product and improve the rigidity of the seat product. This invention injects high-temperature, low-density raw materials into the outer covering material to form an inner liner. The inner liner can provide additional support for the upper outer covering layer, improving the structural stability of the seat product. This method can produce product structures that cannot be manufactured by traditional processes. In this invention, when high-temperature, low-density raw materials come into contact with partially solidified outer coating materials, they can promote secondary foaming of some high-density raw materials. The degree of foaming is affected by the temperature gradient, and a gradual density change can be formed at the interface between the two, making the seat product seamless inside and out with strong integrity. This invention allows for the even distribution of stress when the seat product undergoes slight deformation under pressure, preventing damage to the seat product and giving it excellent flexibility. This significantly improves seating comfort. Compared to seat products made of a single material and density on the market, seat products with multiple material combinations and assembled seat products are more robust, durable, lightweight, and portable, giving them a stronger competitive edge. Attached Figure Description
[0012] Figure 1 This is an appearance drawing of a high-strength, lightweight lumbar support seat cushion according to the present invention; Figure 2 This is a cross-sectional view of a high-strength, lightweight lumbar support seat cushion of the present invention; Figure 3 This is a flowchart illustrating the preparation process of a high-strength, lightweight lumbar support seat cushion according to the present invention.
[0013] The labels in the diagram are: 1. Upper outer covering material; 2. Lower outer covering material; 3. Inner filling; 4. Accommodation space; 5. Outer edge of the seat cushion; 6. Inner edge of the seat cushion. Detailed Implementation
[0014] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.
[0015] The present invention will be further described below with reference to embodiments: Example: Refer to Figure 1 and Figure 2 The present invention first provides a high-strength lightweight lumbar support seat cushion, including an upper outer covering material 1, a lower outer covering material 2, and an inner core 3 connected between the two. The upper outer covering material 1 and the lower outer covering material 2 are integrally formed so that the upper outer covering material 1 and the lower outer covering material 2 form a receiving space 4 for filling the inner core 3. The edges of the upper outer covering material 1 and the lower outer covering material 2 are connected to each other to form the outer edge 5 of the seat cushion. Specifically, the upper outer covering material 1 and the lower outer covering material 2 can be tightly bonded together, which enhances the structural strength of the seat product and also makes the seat product look cleaner and more beautiful.
[0016] Furthermore, the upper outer covering material 1 has multiple first ventilation holes in the middle, and the lower outer covering material 2 has corresponding second ventilation holes in the middle corresponding to the first ventilation holes. The edges of adjacent first and second ventilation holes are connected to form the inner edge 6 of the seat cushion. Specifically, the aligned first and second vent holes not only improve the breathability and comfort of the seat product, but also enhance the stability of the connection between the upper outer covering material 1 and the lower outer covering material 2.
[0017] Furthermore, the density of the upper outer surface covering material 1 and the lower outer surface covering material 2 is greater than the density of the inner liner 3, and the upper outer surface covering material 1, the lower outer surface covering material 2 and the inner liner 3 are made of the same material. The upper outer surface covering material 1 and the lower outer surface covering material 2 are both made of EPS foam material, and the foaming ratio of the raw materials of the upper outer surface covering material 1 and the lower outer surface covering material 2 is lower than the foaming ratio of the raw materials of the inner liner 3. Specifically, EPS is a lightweight, high-strength material with excellent cushioning and insulation properties. It is commonly used in the manufacture of packaging materials, thermal insulation materials, and some lightweight structural components. EPS is composed of countless interconnected, strong hollow spheres, with nearly 97% of its volume being air. Therefore, EPS material is extremely lightweight. Similarly, the hollow structure gives EPS advantages such as low water absorption and high mechanical properties. Furthermore, EPS material has high compressive strength, high creep resistance, corrosion resistance, and aging resistance, which can effectively reduce the weight of seat products. The upper outer covering material 1 and the lower outer covering material 2 have higher densities, making them more robust and providing better support and protection. The inner liner 3 has a lower density because it uses EPS material with a higher foaming ratio, making the inner liner 3 lighter while maintaining a certain degree of structural stability.
[0018] This high-strength, lightweight lumbar support cushion evenly distributes stress when the seat is subjected to slight deformation under pressure, preventing damage to the seat and giving it excellent flexibility. This greatly improves seating comfort. Compared to seat products with a single material and density on the market, seat products with multiple material combinations and assembled seat products are more robust, durable, lightweight, and portable, giving them a stronger competitive edge.
[0019] Reference Figure 3 This embodiment also provides a method for preparing the above-mentioned high-strength lightweight lumbar support cushion, including the following steps: Step 1: Add EPS resin and foaming agents of different mass ratios to two sets of pre-foaming equipment. By controlling the steam pressure, temperature, residence time, and stirring rate in the two sets of foaming equipment, raw materials with low foaming ratio and raw materials with high foaming ratio can be prepared for later use. Place the pre-foamed expandable plastic beads into the pre-foaming equipment and heat it to 110℃-220℃ to further expand and fuse the pre-foamed expandable plastic beads to form a foamed material of a predetermined shape. Generally speaking, the higher the mass ratio of foaming agent, the lower the steam pressure, the higher the temperature, the longer the residence time, and the faster the stirring rate, the higher the foaming ratio of EPS resin. High-density raw materials are used to prepare high-density outer coating materials through casting molding or spraying molding. The process is simple and efficient. The exoskeleton structure formed by the outer coating material can ensure the appearance integrity of the seat product and improve the hardness of the seat product. Step 2: After closing the upper and lower molds, a covering material cavity is formed. A layer of upper outer surface covering material 1 and lower outer surface covering material 2, prepared from raw materials with a low foaming ratio, is then bonded to the inner wall of the covering material cavity. The bonding method includes, but is not limited to, casting or spraying. The molding temperature is controlled between 85℃ and 100℃, and the molding time is controlled between 20 and 60 seconds. The temperature of 85℃-100℃ is slightly lower than the pre-foaming temperature of 110℃-220℃, which promotes the slow solidification of the foamed material. Casting involves injecting the foamed material into the covering material cavity and then adjusting the orientation of the cavity so that the foamed material flows along the covering material. During the material flow process, some of the foamed material will adhere to the inner wall of the covering material cavity, forming a uniform outer covering material. The spraying method involves spraying the foamed material into the inner wall of the covering material cavity through a pump, whereby the foamed material will adhere to the inner wall of the covering material cavity, similarly forming a uniform outer covering material. It is worth noting that both of the above methods can form an outer covering material with an uneven inner wall. By injecting high-temperature, low-density raw materials into the outer covering material to form an inner liner, the inner liner can provide additional support for the upper outer covering layer, improving the structural stability of the seat product. This method can produce product structures that cannot be manufactured by traditional processes. Step 3: After injecting high-expansion-ratio raw materials into the space 4 between the upper outer covering material 1 and the lower outer covering material 2 and continuing to cool, the filling liner 3 is formed. The high-expansion-ratio raw materials and the incompletely solidified low-expansion-ratio raw materials adhere to each other to form the bonding interface between the upper outer covering material 1, the lower outer covering material 2 and the filling liner 3, thus forming the lumbar support cushion body. The molding temperature is controlled between 45℃ and 70℃ until the upper outer covering material 1, the lower outer covering material 2 and the filling liner 3 reach the same temperature. The temperature of 45℃-70℃ is much lower than the pre-foaming temperature of 110℃-220℃, which can promote the rapid solidification and molding of the foaming material. When the high-temperature low-density raw materials come into contact with the incompletely solidified outer covering material, they can promote the secondary foaming of some high-density raw materials. The degree of foaming is affected by the temperature gradient, which can form a gradual density change at the interface between the two, making the seat product seamless inside and out with strong integrity. Step 4: After the upper and lower molds are separated, the formed lumbar support cushion body is taken out and cooled to room temperature for a second time. The second cooling method includes, but is not limited to, air cooling or water cooling.
[0020] The embodiments disclosed herein are preferred embodiments, but are not limited thereto. Those skilled in the art can readily grasp the spirit of the present invention based on the above embodiments and make different extensions and variations, but as long as they do not depart from the spirit of the present invention, they are all within the protection scope of the present invention.
Claims
1. A high-strength, lightweight lumbar support seat cushion, comprising an upper outer covering material (1), a lower outer covering material (2), and an inner core (3) connecting the two, characterized in that, The upper outer surface covering material (1) and the lower outer surface covering material (2) are integrally formed so that the upper outer surface covering material (1) and the lower outer surface covering material (2) form a receiving space (4) for filling the inner liner (3). The density of the upper outer covering material (1) and the lower outer covering material (2) is greater than that of the inner liner (3), and the upper outer covering material (1), the lower outer covering material (2) and the inner liner (3) are made of the same material.
2. The high-strength, lightweight lumbar support cushion as described in claim 1, characterized in that, The upper outer surface covering material (1) and the lower outer surface covering material (2) are both made of EPS foam material, and the foaming ratio of the raw materials of the upper outer surface covering material (1) and the lower outer surface covering material (2) is lower than the foaming ratio of the raw materials of the inner liner (3).
3. The high-strength, lightweight lumbar support cushion as described in claim 1, characterized in that, The edges of the upper outer covering material (1) and the lower outer covering material (2) are connected to form the outer edge (5) of the cushion.
4. A high-strength, lightweight lumbar support cushion as described in claim 1, characterized in that, The upper outer covering material (1) has multiple first ventilation holes in the middle, and the lower outer covering material (2) has corresponding second ventilation holes in the middle corresponding to the first ventilation holes. The edges of adjacent first and second ventilation holes are connected to form the inner edge (6) of the seat cushion.
5. A method for preparing a high-strength lightweight lumbar support cushion as described in any one of claims 1-4, characterized in that, Includes the following steps: Step 1: Add EPS resin and foaming agent of different mass ratios to two sets of pre-foaming equipment. By controlling the steam pressure, temperature, residence time and stirring rate in the two sets of foaming equipment, raw materials with low foaming ratio and raw materials with high foaming ratio can be prepared for later use. Step 2: After the upper mold and the lower mold are closed, a covering material cavity is formed. A layer of upper outer surface covering material (1) and lower outer surface covering material (2) made of raw materials with low foaming ratio are bonded and formed on the inner wall of the covering material cavity. Step 3: After injecting high foaming ratio raw materials into the space (4) between the upper outer covering material (1) and the lower outer covering material (2), the filling liner (3) is formed by continuous cooling. The high foaming ratio raw materials and the low foaming ratio raw materials that have not been completely solidified adhere to each other to form the adhesion interface between the upper outer covering material (1), the lower outer covering material (2) and the filling liner (3), so as to form the lumbar support cushion body. Step 4: After the upper and lower molds are separated, remove the formed lumbar support cushion body and cool it to room temperature a second time.
6. The method for preparing a high-strength lightweight lumbar support cushion as described in claim 5, characterized in that, The bonding and molding methods in step two include, but are not limited to, casting molding and spraying molding.
7. The method for preparing a high-strength lightweight lumbar support seat cushion as described in claim 5, characterized in that, In step two, the molding temperature is controlled between 85℃ and 100℃, and the molding time is controlled between 20 seconds and 60 seconds.
8. The method for preparing a high-strength lightweight lumbar support seat cushion as described in claim 5, characterized in that, The molding temperature in step three is controlled between 45℃ and 70℃ until the upper outer covering material (1), the lower outer covering material (2), and the filling liner (3) are all at the same temperature.