SYSTEM AND METHOD FOR CONCEALING SPRING BURST

Abstract

System for concealing ridge (F) in a suspended seat (S), comprising: - a frame (24) comprising a channel (28) with at least one channel wall (26); - a seat (12) made of textile fabric; and - a support (10) injection-molded onto the seat surface (12), wherein the support (10) has a support wall, wherein the support (10) is injection-molded onto the seat surface (12) such that the seat surface (12) extends from the support wall (16), wherein the support (10) and part of the seat (12) are positioned at a connection point (32) of the support (10) and the seat (12) in the channel (28) such that the part of the seat (12) rests against the channel wall (26) in such a way that a ridge (F) formed at the connection point (32) of the support (10) and the seat (12) is positioned against the channel wall (26), wherein, when the seat (12) and the support (10) are positioned in the frame (24), a part (30) of the seat (12), which adjoins the connection point (32) of the support (10) and the seat (12), extends between the support (10) and the channel wall (26) along the support (10), and where the ridge (F) is not exposed on the upper support wall (16).

Description

CROSS-REFERENCE TO RELATED LOGIN DATA

[0001] The present application claims the benefit and priority of the preliminary US patent application filed on April 9, 2019, with serial number 62 / 831,527 and entitled SYSTEM AND METHOD FOR HIDING MOLDING FLASH. BACKGROUND

[0002] The present disclosure relates to a system and a method for concealing injection molding flash and in particular a system and a method for concealing injection molding flash in a suspension member, such as a suspension textile for seats.

[0003] Suspended textile seat surfaces have found widespread use as an alternative to hard and foam-padded surfaces. Such suspended textile seat surfaces can offer the comfort of foam-padded surfaces at a similar weight to hard plastic seats and at a relatively low cost. Advantageously, suspended textile seats offer enhanced comfort by utilizing a preset tension in the fabric, which can be adjusted to provide a responsive force tailored to individual comfort preferences.

[0004] It is common knowledge that in the production of suspension fabric seats, the fabric seat surface is overmolded with a polymer to form a support. The support and the fabric are then joined to form a seat frame. During the support injection molding process, the fabric is positioned and clamped between two halves of an injection mold. When clamped together, the mold halves define a cavity in which the support is formed. A polymer is injected into this cavity over the fabric to create the overmolded support.

[0005] The injection molding process is carried out under relatively high pressure. Therefore, tooling conditions near the parting line P (see, for example, Figure 2), which is the line along which the mold halves meet, are designed to ensure that maximum clamping forces are concentrated near the parting line. This is intended to maximize the pressure near the cavity edge to minimize or prevent plastic from being pushed beyond parting line P. Flash occurs when plastic leaks past parting line B. If conventional design rules are followed—that is, if the mold halves are clamped tightly together without anything obstructing the cavity edges—the injection molding process produces flash-free products over thousands of cycles.

[0006] However, if an object is inserted between the mold halves, burrs can form due to gaps at the mating surfaces or along the parting line P. For example, if a support is injection-molded onto a fabric seat, problems can arise because the fabric is positioned between the mold halves and prevents them from closing completely. Due to the porous nature of the fabric and the open spaces (open weave) between the weft fibers W and the warp fibers R in the fabric (see, for example, 1A and 1B), the mold halves will not close and seal completely to form a reliable condition for the parting line P.Thus, two problems arise when injection molding onto the textile fabric: 1) the thickness of the textile fabric prevents the two halves of the mold from touching, thereby preventing sealing or closing of the parting line P; and 2) the textile fabric itself is not homogeneous, so openings in the fabric's weave allow the plastic to flow through the openings in the fabric. Figures 2 and 3 depict a fabric with a thermoplastic ring and burr injection molded onto the textile fabric, resulting from the plastic crossing the parting line P. Areas between the filler R rows or between the monofilament W rows may contain burrs or finger burrs of varying dimensions. Figure 3 shows the finger-like burr F.

[0007] Plastic flowing behind the dividing line P on the fabric surface between the filler or warp rows forms the burr. These burr peninsulas are called finger burrs because the burr "rows" are often separated like fingers on a hand. When a finger burr forms, it eventually breaks off from the fabric after several cycles. When it breaks off, the finger burr tends to protrude at an angle from the fabric surface (see 5A and 5B). When the seat surface (the fabric surface and the support) is installed in the seat frame, finger burr projections subjected to fabric tension can stand upright and catch on the skin or clothing of a seat user.

[0008] From US patent 3,844,612 A, it is known that in seating furniture or a seat, each opposing edge region of a flexible seat or back support element is attached to a strip having a groove that diverges outwards with respect to the longitudinal center plane of the piece of furniture or seat, wherein the strip is detachably installed in a recess in the frame of the piece of furniture or seat and is complementary to it.

[0009] Document US 6,966,606 B2 relates to a fastening device for a load-bearing fabric. The fastening device comprises an expandable beam attached to a stretched load-bearing fabric. To attach the beam to the frame, the beam and the fabric are stretched together into the desired shape and fastened to a support frame.

[0010] Document US 8,708,418 B2 relates to a vehicle seat comprising: a flat elastic body having a frame body provided on a circumference of the flat elastic body, the flat elastic body being stretched against the frame body; a padding element arranged around the flat elastic body; and a spinal element, wherein a support surface designed to support a seated person is formed by the flat elastic body and the padding element.

[0011] Document US 2005 / 0194829 A1 relates to a furniture component comprising a base element with a flared edge and a first fastening element. The first fastening element comprises a channel, and the flared edge is arranged within the channel. The furniture component also comprises a fabric piece arranged around at least part of the first fastening element. The furniture component further comprises a second fastening element arranged around the first fastening element, with the fabric piece being fastened between the first and second fastening elements.

[0012] The publication EP 2 120 648 B1 relates to a seat construction comprising an articulated seat and backrest. The rear part of the seat automatically pivots relative to the front part when the seat is tilted between an upright and a reclined position. The upper part of the backrest pivots relative to the lower part between a neutral position and an extended position, with the upper part pivoting independently of the backrest's tilt position relative to the lower part.

[0013] There is a need for a system that includes a seat and a method for a suspended textile seat support and surface that prevents burrs from protruding from the surface. With such a textile seat support and surface, the burr is hidden from the user and cannot be touched by the user or their clothing, thus preventing it from becoming entangled. SUMMARY

[0014] The problem underlying the invention is solved by a system according to independent claim 1, wherein advantageous embodiments of the system according to the invention are specified in dependent claims 5 and 6. The problem underlying the invention is further solved by a method according to dependent claim 7, wherein advantageous embodiments of the method according to the invention are specified in dependent claims 8 to 12.

[0015] Accordingly, the invention relates to a system for concealing burrs in a suspension seat, comprising a frame with a channel having at least one wall, a textile seat surface, and a support molded onto the seat surface. The support has a wall and is molded onto the seat surface such that the seat surface extends from the wall outwards from the support. In embodiments, the textile seat surface is a woven material.

[0016] The support and a portion of the seat surface at a junction between the support and the seat surface are positioned within the channel, with the portion of the seat surface abutting the channel wall such that the ridge formed at the junction of the support and the seat surface is positioned against the channel wall. The support is defined by a dividing line, and the seat surface extends from the support along this dividing line. In this embodiment, the dividing line points towards the channel wall.

[0017] In one embodiment, the support has an upper wall and a lower wall, and the wall from which the seat extends is a side wall. The channel wall can also be a side wall, so that the ridge between the support side wall and the channel side wall is enclosed. In a preferred embodiment, no ridge is exposed on the upper support wall.

[0018] In another aspect, a suspended seat comprises a seat surface and a support molded onto the seat surface, such that the seat surface extends from the wall. The seat includes a frame with a wall, and the support and part of the seat surface at a junction between the support and the seat surface are positioned within the frame, with part of the seat surface abutting the frame wall. The ridge formed at the junction of the support and the seat surface is isolated between the support wall and the frame wall.

[0019] In one embodiment, the support wall is an inner wall, and the support further comprises an upper and a lower wall and an outer wall. The frame may have a channel formed within it, and the frame wall forms an inner wall of the channel. The channel further comprises an outer wall and a lower wall. When positioned in the channel, the portion of the seat surface is enclosed between the inner wall of the support and the frame wall, and no ridge is exposed behind the inner wall of the support and the frame wall.

[0020] The invention further relates to a method for concealing burrs in a suspension seat by injection molding a carrier onto a textile seat surface. The carrier is formed with a wall and is injection molded onto the seat surface in such a way that the seat surface extends from the carrier wall.

[0021] The process involves positioning the injection-molded support and seat surface within a seat frame against a wall of the seat frame. The support and a portion of the seat surface at a joint between the support and the seat surface are positioned within the seat frame, with that portion abutting the seat frame wall. Any burr formed at the joint between the support and the seat surface is positioned against the seat frame wall and is not exposed to a user of the seat.

[0022] The method comprises forming the seat frame with a channel such that the seat and the support can be positioned in the channel, with a portion of the seat extending along the support between the support wall and the channel, adjacent to the junction of the support and the seat, to capture any ridge between the support wall and the frame wall. Furthermore, the method may include fixing the support in the frame by means of, for example, fasteners. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] After reviewing the following detailed description and accompanying drawings, the advantages and benefits of the present embodiments will be more readily apparent to a person skilled in the relevant field, wherein: Fig. 1A and Fig. 1B Representations of textile fabrics are those that depict a known suspension seat base formed from warp and weft fibers; Fig. 2 and Fig. 3. Represent a support molded onto a textile seat surface and show the burr that forms behind the mold around the textile fabric; Fig. 4 is a sectional view showing the ridge that projects from the beam at the support / seat connection point; Fig. 5A and Fig. 5B the finger ridge after injection ( Fig. 5A) and the raised finger burr after several textile tension cycles ( Fig. 5B); Fig. 6 a (e) flowchart / representation of an overall seat manufacturing process is; Fig. 7 is a representation of an embodiment of an overmolded seat surface and a support according to the present disclosure; Fig. 8A and Fig. 8B is a perspective or side view of the overmolded seat surface and the support, which is positioned above and before insertion into a seat frame; and Fig. 9A and Fig. 9B represents the overmolded seat surface and the support that is inserted into the seat frame ( Fig. 9A) and is arranged therein ( Fig. 9B). DETAILED DESCRIPTION

[0024] Although the present disclosure may be expressed in various forms, one or more embodiments are shown in the drawings and described below with the understanding that the present disclosure is to be regarded only as an illustration and is not intended to limit the disclosure to any particular embodiment described or shown.

[0025] A projecting ridge F from a seat surface, as illustrated in Figures 5A and 5B, can be problematic if it extends along or from the seat surface. It can negatively affect the aesthetics of the seat and can catch on a user's skin or clothing.

[0026] In one embodiment of a system, seat, and method for reducing burrs according to the present disclosure, with reference to 8A-B and 9A-B, a support 10 is injection-molded onto a seat surface 12 such that the seat surface 12 exits the support 10 at a location 14 along a wall of the support 10. In one embodiment, the seat surface 12 extends from or exits the support 10 along a side wall 16 of the support 10 between an upper and lower surface or wall 18, 20 of the support 10 (where the upper wall 18 of the support 10 is flush with a surface 22 of the seat frame 24). This means that the textile fabric forming the seat surface 12 is injected into the support 10 between the upper and lower walls 18, 20 of the support 10 and exits the support 10 at a support / surface connection point shown in general at 32, that is, along a side wall 16 of the support 10.The support / surface connection point 32 is located at the dividing line P of the mold halves.

[0027] As noted above and shown in Figures 1A and 1B, the seat surface 12 may not be a solid surface. That is, the seat surface 12 may be formed from a woven material that has openings in the weave. In a seat surface 12, the surface is a bond of weft fibers W and warp fibers R. The weft fibers W may be, for example, monofilament fibers such as block copolymer monofilament, and the warp fibers R may be filler fibers such as a polyester yarn. In some cases, the fibers forming the fabric may be porous. Thus, when the fabric is positioned and clamped between two halves 40a,b of an injection mold 40, gaps form at the joining point of the mold halves or at the parting line P.When the carrier material 10 is injected into the mold 40 at relatively high pressure, the liquefied material leaks through the parting line P, at least at the points where the fabric is present along the parting line P, and / or may leak through the fabric, forming burrs F.

[0028] After the support 10 has been injection-molded onto the seat surface 12, the support 10 is positioned in the seat frame 24. To prevent the ridge F from being exposed, when positioning the support 10 in the seat frame 24, the wall 16 of the support 10, from which the seat surface 12 emerges, is positioned along a wall 26 of the frame channel 28. That is, the support wall 16, from which the seat surface 12 exits the support 10, is concealed within the seat frame channel 28. In this way, the portion of the seat surface 12 (shown at 30) is embedded directly next to the support 10 between the support wall 16 (above the support / surface interface 32) and the side wall 26 of the frame channel. The ridge F, which is formed when the support 10 is injection-molded onto the seat 12, is also embedded between the support 10 and the channel wall 26 by the part 30 of the seat surface 12 embedded between the support 10 and the channel wall 26 next to the support 10.This “hides” the ridge F by embedding it in an unseen area of ​​the seat S, preventing the ridge F from extending from the seat surface 12, which could otherwise detract from the aesthetics of the seat and catch on the user’s clothing or skin.

[0029] In the illustrated embodiment, the seat surface 12 extends from the support 10 along a side wall 16 of the support, which is located next to a side wall 26 of the frame channel 28, so that the support side wall 16 and the ridge F are concealed within the channel 28. Furthermore, it is conceivable that the wall from which the seat surface 12 (and the ridge F) extend from the support 10 could be a floor or lower wall, which would result in the exit wall being concealed, so that the ridge F is held within the channel 28, hidden, and does not touch the user of the seat.

[0030] A method for concealing a burr F in a suspension seat S involves injection-molding a carrier 10 onto a textile seat surface 12. The carrier 10 has a wall and is injection-molded onto the seat surface 12 such that the seat surface 12 extends from the wall. In one method, the carrier wall from which the seat surface 12 emerges is a side wall 16.

[0031] The process involves positioning the injection-molded support 10 and the seat surface 12 in a channel 28 within a seat frame 24. The channel 28 has at least one wall, and the support 10 and a portion 30 of the seat surface 12 at a connection point 32 of the support 10 and the seat surface 12 are positioned in the channel 28, with the portion 30 of the seat surface 12 abutting the wall of the channel 28. In this way, any ridge F formed at the connection point 32 of the support 10 and the seat surface 12 is positioned against the wall of the channel 28.

[0032] In one method, the wall is a side wall 26 of the channel 28. The channel 28 can be formed by at least two walls and preferably three walls to enclose the support 10 within the channel 28. Furthermore, the method can include fixing the support 10 within the channel 28. The support 10 can be fixed within the channel 28 in various ways, such as by fasteners 44, adhesives, welding, and the like.

[0033] Fig.Figure 6 generally describes a process for manufacturing and assembling a seat S, which has a seat surface 12, into a frame 24. In step 52, the seat surface material 12 can first be cut to a suitable size and positioned in the open injection mold 40. The mold 40 is closed on the material, and in step 54, the carrier material 10 is injected onto the seat surface material 12. At this point, flash F may (and is expected to) be present where the seat surface material 12 is captured between the closed mold halves 40a, b (at the parting line P). If necessary, in step 56, excess seat surface material 12 can be trimmed around the outside of the carrier 10.

[0034] In step 58, the seat frame 24 is formed, for example by injection molding, and in step 60, the seat surface 12 with the molded-on support 10 is attached to the frame 24, for example by pressing the support 10 into the frame 24. The support 10 and the seat surface 12 can then be fixed in the frame 24 using, for example, fastening elements 44.

[0035] It is understood that by repositioning the form separation line P of the support 10 (which is the line formed where the form halves 40a, b meet and where the seat surface 12 exits the support 10 at the support / seat surface connection point 32) at a point in the frame channel 28, the separation line P is concealed and any impact on the aesthetics and comfort-related surfaces of the seat is avoided. That is to say, the separation line P is hidden from the user and cannot be touched.

[0036] Furthermore, by repositioning the parting line P, the injection molding process can be opened up to a wider range of operating parameters, such as increased injection pressures, increased parting line tonnage, different resin viscosities, and packing pressure. Some of these extended operating parameter ranges can also help to reduce scrap resulting from the injection molding process. Since changes in textile dimensions and porosity can also influence the generation of flash F, the present system and method for concealing flash F also enable a greater variety and different types of suspension textiles.

[0037] Furthermore, it should be obvious that the present system and method for concealing injection molding flash (F) provide design and material freedom that is unattainable in previously known seat designs (S). Such a system, seat, and method minimize or eliminate visible flash (F) and parting lines (P), which would otherwise detract from the aesthetics and comfort of such seats (S).

[0038] In the present disclosure, the terms "a" or "an" are intended to include both the singular and the plural. Conversely, any reference to plural elements, where appropriate, is intended to include the singular. It is obvious to the person skilled in the art that the directional terms, such as upper, lower, rear, front, and the like, serve only for clarification and are not intended to limit the scope of protection of the disclosure.

[0039] From the foregoing, it can be concluded that numerous modifications and variations can be implemented without deviating from the true nature and scope of protection of the new concepts presented in this film. It is understood that no limitation regarding specific depicted embodiments is intended or should be inferred.

Claims

[1] System for concealing ridge (F) in a suspended seat (S), comprising: - a frame (24) comprising a channel (28) with at least one channel wall (26); - a seat (12) made of textile fabric; and - a support (10) injection-molded onto the seat surface (12), wherein the support (10) has a support wall, wherein the support (10) is injection-molded onto the seat surface (12) such that the seat surface (12) extends from the support wall (16), wherein the support (10) and part of the seat (12) are positioned at a connection point (32) of the support (10) and the seat (12) in the channel (28) such that the part of the seat (12) rests against the channel wall (26) in such a way that a ridge (F) formed at the connection point (32) of the support (10) and the seat (12) is positioned against the channel wall (26), wherein, when the seat (12) and the support (10) are positioned in the frame (24), a part (30) of the seat (12), which adjoins the connection point (32) of the support (10) and the seat (12), extends between the support (10) and the channel wall (26) along the support (10), and where the ridge (F) is not exposed on the upper support wall (16). [2] System according to claim 1, wherein the support (10) has an upper wall (18) and a lower wall (20) and wherein the support wall (16) from which the seat surface (12) extends is a side wall of the support (10). [3] System according to claim 1 or 2, wherein the channel wall (26) is a side wall of the channel (28). [4] System according to any one of claims 1 to 3, wherein the textile material of the seat surface (12) is a woven material. [5] System according to any one of claims 1 to 4, wherein the seat surface (12) extends from the support (10) along a dividing line (P) in the support (10) and wherein the dividing line (P) points to the channel wall (26). [6] System according to one of the preceding claims, wherein the system includes a suspended seat (S) comprising the seat surface (12) with the injection-molded support (10) and the frame (24). [7] Method for concealing burr (F) in a suspended seat (S), comprising: - Injection molding of a support (10) onto a seat surface (12) made of textile fabric, wherein the support (10) has a support wall (16), wherein the support (10) is injection molded onto the seat surface (12) such that the seat surface (12) extends from the support wall (16); and - Positioning the injection-molded carrier (10) and the seat surface (12) in a frame (24), wherein the frame (24) has a frame wall, wherein the support (10) and a part (30) of the seat (12) are positioned at a connection point (32) of the support (10) and the seat (12) in the frame (24) such that the part (30) of the seat (12) rests against the frame wall, such that any ridge (F) formed at the connection point (32) of the support (10) and the seat (12) is positioned against the frame wall and is not exposed to a user of the seat (S), wherein, when the seat (12) and the support (10) are positioned in the channel (28), a part (30) of the seat (12) extends along the support (10) next to the connection point (32) of the support (10) and the seat (12) between the support wall (16) and the channel (28) to form a ridge (F) between the support wall (16) and the frame wall. [8] Method according to claim 7, wherein the support wall (16) from which the seat surface (12) extends is a side wall of the support (10). [9] Method according to claim 7 or 8, wherein the frame (24) has a channel (28), wherein the frame wall forms part of the channel (28). [10] Method according to any one of claims 7 to 9, which further includes fixing the carrier (10) in the frame (24). [11] Method according to claim 10, wherein the support (10) is fixed in the frame (24) by means of fastening elements. [12] Method according to any one of claims 7 to 11, wherein the carrier (10) is injection molded such that it has a parting line (P) and wherein the seat surface (12) extends from the parting line (P).

Images