阅读说明：本技术 复合纤维座垫及其制造方法 (Composite fiber seat cushion and manufacturing method thereof ) 是由 刘芳玲 于 2020-05-25 设计创作，主要内容包括：一种复合纤维座垫及其制造方法,复合纤维座垫的制造方法包含下列步骤：(1)制备可挠性的编织束且弯折至U型；(2)将所述编织束靠抵辅助模具的其中一面并使所述编织束朝所述辅助模具另一面弯折；(3)制备多片纤维布,并将所述编织束、所述辅助模具及所述纤维布置入内部中空的成型模具,所述纤维布相叠设置于所述辅助模具另一面；(4)将树脂注入至所述成型模具内部；(5)加热所述成型模具使包覆所述编织束及所述纤维布的树脂固化；(6)自所述成型模具取出成品；及(7)移除辅助模具,并清洁成品。本发明功效在于通过一同将所述纤维布及所述编织束浸入树脂,加热树脂使所述纤维布及所述编织束一同受加热固化的树脂包覆,并制得具有更高耐破坏强度的复合纤维座垫。(A composite fiber seat cushion and a manufacturing method thereof, the manufacturing method of the composite fiber seat cushion comprises the following steps: (1) preparing a flexible braided bundle and bending the braided bundle to a U shape; (2) abutting the weaving bundle against one surface of an auxiliary die and bending the weaving bundle towards the other surface of the auxiliary die; (3) preparing a plurality of pieces of fiber cloth, and putting the weaving bundles, the auxiliary die and the fiber cloth into a forming die with a hollow interior, wherein the fiber cloth is arranged on the other surface of the auxiliary die in an overlapped manner; (4) injecting a resin into the inside of the molding die; (5) heating the forming die to solidify the resin coating the weaving bundles and the fiber cloth; (6) taking out a finished product from the forming die; and (7) removing the auxiliary mold and cleaning the finished product. The invention has the advantages that the fiber cloth and the weaving bundles are immersed into resin together, the resin is heated to ensure that the fiber cloth and the weaving bundles are coated by the resin which is heated and solidified together, and the composite fiber seat cushion with higher breaking strength is prepared.)

1. The utility model provides a composite fiber seatpad, is applicable to the seat pole of bicycle, composite fiber seatpad contains seatpad body and seat bow unit, its characterized in that: the composite fiber seat cushion also comprises a curing unit, wherein the curing unit comprises a body layer for coating the seat cushion body and a seat bow layer for coating the seat bow unit, the body layer and the seat bow layer are integrally made of the same material, the seat cushion body comprises a plurality of pieces of overlapped fiber cloth, and the fiber cloth jointly forms a rear seat part for sitting and a front side part extending forwards from the rear seat part; the seat bow unit is used for being fixedly connected with the seat rod and comprises two installation rods which are located below the seat cushion body and respectively define two transversely-communicated gaps with the seat cushion body, the installation rods are made of the same material as the fiber cloth, and each installation rod is provided with a rear end portion corresponding to the rear seat portion and a front end portion corresponding to the front side portion.

2. The composite fiber seat cushion according to claim 1, wherein: the front end portion of the seat bow unit is connected to the front side portion, and the rear end portion is connected to the rear seat portion.

3. The composite fiber seat cushion according to claim 1, wherein: the seat cushion body and the seat bow unit are made of carbon fiber wires.

4. The composite fiber seat cushion according to claim 1, wherein: any two adjacent fiber cloths in the fiber cloth are overlapped in different fiber arrangement directions.

5. A manufacturing method of a composite fiber seat cushion is characterized in that: the manufacturing method comprises the following steps:

(A) respectively preparing a flexible braided bundle, a plurality of pieces of fiber cloth, an auxiliary mould and a forming mould with a hollow interior, bending the braided bundle to be approximately U-shaped, forming the braided bundle into two mounting rods, wherein each mounting rod is provided with a rear end part and a front end part opposite to the rear end part, and the front end parts are connected with each other;

(B) the auxiliary mould comprises a near-base bow surface and a near-body surface opposite to the near-base bow surface, the weaving bundle is abutted against the near-base bow surface of the auxiliary mould and bent towards the direction of the near-body surface, and the front end part and the rear end part are protruded to the near-body surface;

(C) placing the weaving bundle, the auxiliary mold and the fiber cloth into the forming mold together, wherein the fiber cloth is overlapped and arranged on the surface, close to the body, of the auxiliary mold, and is covered by the fiber cloth and contacts the front end part and the rear end part;

(D) injecting resin through an injection hole of the forming die to fill the inside of the forming die with the resin, so that the weaving bundles and the fiber cloth are impregnated with the resin;

(E) heating the forming die to a temperature range, and solidifying the resin coating the braided bundles and the fiber cloth to obtain the composite fiber seat cushion;

(F) taking out the auxiliary die and the composite fiber seat cushion from the forming die; and

(G) and removing the auxiliary die attached to the composite fiber seat cushion to obtain a finished product of the composite fiber seat cushion.

6. The method for manufacturing a composite fiber seat cushion according to claim 5, wherein: the step (C) includes a step (C1), a step (C2), and a step (C3), in the step (C1), the forming mold further includes an upper mold part and a lower mold part having a groove, the knitting yarn and the auxiliary mold are turned over first, the knitting yarn is inserted downward between the groove and the auxiliary mold, in the step (C2), the fiber cloth is stacked and placed downward on the near-body surface so as to cover and contact the front end portion and the rear end portion, and then, in the step (C3), the upper mold part is engaged downward with the lower mold part to complete mold clamping.

7. The method for manufacturing a composite fiber seat cushion according to claim 5, wherein: the manufacturing method further includes a step (H) of cutting and separating the front end portion and cutting the front end portion and the rear end portion into a strip shape, between the step (a) and the step (B).

8. The method for manufacturing a composite fiber seat cushion according to claim 5, wherein: in the step (a), the auxiliary mold is a wax mold.

9. The method for manufacturing a composite fiber seat cushion according to claim 5, wherein: in the step (C), the weaving bundle, the auxiliary mold, and the fiber cloth are placed together in the forming mold, any two adjacent pieces of the fiber cloth are stacked in different fiber arrangement directions, and the fiber cloth is placed on the proximal surface of the auxiliary mold and covered with the fiber cloth to contact the front end portion and the rear end portion.

Technical Field

The invention relates to a seat cushion, in particular to a composite fiber seat cushion and a manufacturing method thereof.

Background

Referring to fig. 1, a conventional seat cushion 1 for a bicycle is adapted to a seat post (not shown) of the bicycle, and the seat cushion 1 includes a seat cushion body 11 for seating, a seat bow unit 12 for mounting the seat post, and a connecting shell frame 13 for fixedly connecting the seat cushion body 11 and the seat bow unit 12. The seat cushion body 11 has a filling material 112 and a surface cloth 111 covering the filling material 112, and the filling material 112 may be selected from one of silica gel or foam.

With the advance of material technology, referring to fig. 2, another conventional bicycle seat cushion 2 includes a seat cushion body 21 for seating, a seat bow unit 22 for mounting the seat post, and a connecting shell 23 for fixedly connecting the seat cushion body 21 and the seat bow unit 22. The seat body 21 is made by laminating a plurality of carbon fiber sheets and impregnating the carbon fiber sheets with resin and then heating the carbon fiber sheets.

However, when the seat cushion body 21 is to be installed on the connecting shell 23, an adhesive is additionally used to fix the seat cushion body 21 and the connecting shell 23 and the seat bow unit 22, so that the seat cushion 2 is easily broken from the heterogeneous bonding position between the seat cushion body 21 and the connecting shell 23 or the heterogeneous bonding position between the connecting shell 23 and the seat bow unit 22 after long-term use, and the seat cushion body 21, the seat bow unit 22 and the connecting shell 23 are separated and damaged.

Disclosure of Invention

Accordingly, an object of the present invention is to provide a composite fiber seat pad having higher fracture strength and a method for manufacturing the same.

Accordingly, the composite fiber seat cushion of the present invention is suitable for a seat post of a bicycle, and includes a seat cushion body, a seat bow unit, and a curing unit. The curing unit comprises a body layer for coating the seat cushion body and a seat bow layer for coating the seat bow unit, the body layer and the seat bow layer are integrally made of the same material, the seat cushion body comprises a plurality of pieces of overlapped fiber cloth, and the fiber cloth jointly forms a rear seat part for sitting and a front side part extending forwards from the rear seat part; the seat bow unit is used for being fixedly connected with the seat rod and comprises two installation rods which are located below the seat cushion body and respectively define two transversely-communicated gaps with the seat cushion body, the installation rods are made of the same material as the fiber cloth, and each installation rod is provided with a rear end portion corresponding to the rear seat portion and a front end portion corresponding to the front side portion.

In the composite fiber seat cushion of the present invention, the front end portion of the seat bow unit is connected to the front side portion, and the rear end portion is connected to the rear seat portion.

According to the composite fiber seat cushion, the seat cushion body and the seat bow unit are made of carbon fiber wires.

According to the composite fiber seat cushion, any two adjacent pieces of fiber cloth are overlapped in different fiber arrangement directions.

Thus, the method for manufacturing the composite fiber seat cushion of the present invention comprises the steps of: (A) respectively preparing a flexible braided bundle, a plurality of fiber cloths, an auxiliary mould and a forming mould with a hollow interior, bending the braided bundle to be approximately U-shaped, and enabling the braided bundle to form two mounting rods, wherein each mounting rod is provided with a rear end part and a front end part opposite to the rear end part, and the front end parts are connected with each other. (B) And abutting the weaving bundle against a proximal arch surface in the auxiliary mold, and bending the weaving bundle towards a proximal body surface in the auxiliary mold, so that the front end part and the rear end part protrude to the proximal body surface. (C) And putting the weaving bundle, the auxiliary die and the fiber cloth into the forming die, wherein the fiber cloth is overlapped and arranged on the surface close to the body of the auxiliary die, and covers and contacts the front end part and the rear end part. (D) And injecting resin through an injection hole of the forming die to fill the inside of the forming die with the resin, so that the weaving bundle and the fiber cloth are impregnated with the resin. (E) And heating the forming die to a temperature range to solidify the resin coating the weaving bundles and the fiber cloth. (F) And taking out the auxiliary die and the composite fiber seat cushion from the forming die. (G) And removing the auxiliary die attached to the composite fiber seat cushion to obtain a finished product of the composite fiber seat cushion.

In the method for manufacturing a composite fiber seat pad according to the present invention, the step (C) includes a step (C1), a step (C2), and a step (C3), in the step (C1), the forming mold further includes an upper mold part and a lower mold part having a groove, the braid and the auxiliary mold are reversed so that the braid is inserted downward between the groove and the auxiliary mold, in the step (C2), the fiber cloth is stacked and downwardly disposed on the near-body surface so as to cover and contact the front end portion and the rear end portion, and then in the step (C3), the upper mold part is downwardly engaged with the lower mold part to complete mold clamping.

The method for manufacturing a composite fiber seat cushion of the present invention further includes a step (H) of cutting and separating the front end portion and cutting the front end portion and the rear end portion into a strip shape in the step (H), the step (H) being located between the step (a) and the step (B).

In the method for manufacturing a composite fiber seat cushion of the present invention, the auxiliary mold in the step (a) is a wax mold.

In the step (C), the braided bundle, the auxiliary mold, and the fiber cloth are placed together in the forming mold, any two adjacent pieces of the fiber cloth are stacked in different fiber arrangement directions, the fiber cloth is placed on the near-body surface of the auxiliary mold, and the fiber cloth covers and contacts the front end portion and the rear end portion.

The invention has the beneficial effects that: through the auxiliary mold makes weave the bundle and buckle to corresponding the shape of auxiliary mold, recycle fibre cloth is overlapped and is covered the another side of auxiliary mold makes fibre cloth reach weave the rudiment that the bundle outward appearance is close the seatpad, and will weave the bundle auxiliary mold reaches fibre cloth is together buckled and is supported forming die, and pours into resin into and heats, makes weave the bundle reach fibre cloth impregnating resin just solidifies because of heating to a brief step makes a composite fiber seatpad that has high resistant breaking strength.

Drawings

Other features and effects of the present invention will be apparent from the embodiments with reference to the accompanying drawings, in which:

FIG. 1 is an exploded perspective view of a seat cushion of a conventional bicycle;

FIG. 2 is an exploded perspective view of another prior art bicycle seat cushion;

FIG. 3 is an exploded perspective view of a seat body and a seat arch unit of one embodiment of the composite fiber seat cushion of the present invention;

FIG. 4 is a perspective view of the embodiment;

FIG. 5 is a cross-sectional view taken along line V-V of FIG. 4;

FIG. 6 is a flow chart of a method of manufacturing the embodiment;

fig. 7 is an exploded perspective view illustrating a relative positional relationship between the braided bundle and the auxiliary mold before turning over in the manufacturing method;

fig. 8 is an exploded perspective view illustrating a relative positional relationship with the molding die after the weaving bundle, the auxiliary die, and the fiber cloth are turned over in the manufacturing method; and

fig. 9 is an exploded perspective view similar to fig. 8, illustrating a state where the braid, the auxiliary mold, and the fibers are arranged into the lower mold part in the manufacturing method.

Detailed Description

Referring to fig. 3, 4 and 5, an embodiment of the composite fiber seat cushion 3 of the present invention is suitable for a seat post (not shown) of a bicycle, and includes a seat cushion body 4, a seat bow unit 5 for being fixed to the seat post, and a curing unit 6 covering the seat cushion body 4 and the seat bow unit 5.

The seat cushion body 4 includes four pieces of fiber cloth 41 made of carbon fiber yarn (12K), any two adjacent pieces of the fiber cloth 41 are stacked in different fiber arrangement directions, and the fiber cloth 41 jointly forms a rear seat portion 411 for seating and a front side portion 412 extending forward from the rear seat portion 411. It should be noted that the material of the fiber cloth 41 may also be glass fiber or ultra-fine metal wire, and the fiber cloth 41 may also be stacked in a plurality of pieces, but in this embodiment, the number of the fiber cloth 41 is still preferably four.

The seat bow unit 5 includes two mounting rods 51 located below the seat cushion body 4 and respectively defining two transversely penetrating gaps 513 with the seat cushion body 4, each mounting rod 51 having a rear end portion 511 corresponding to the rear seat portion 411 and a front end portion 512 corresponding to the front side portion 412, the front end portions 512 being connected to each other and to the front side portion 412, and the rear end portion 511 being also connected to the rear seat portion 411.

The curing unit 6 includes a body layer 61 covering the seat cushion body 4 and a seat arch layer 62 covering the seat arch unit 5, and the body layer 61 and the seat arch layer 62 are integrally formed of the same material.

Referring to fig. 6 and fig. 7-9, the manufacturing method of the embodiment includes steps 701-710:

step 701, respectively preparing a flexible braided bundle 50 formed by co-braiding carbon fiber wires (48K) and carbon fiber wires (3K), an auxiliary mold 91, four pieces of fiber cloth 41 made of carbon fiber wires (12K), and a hollow forming mold 92, bending the braided bundle 50 into a substantially U shape, so that the braided bundle 50 forms two mounting rods 51, each mounting rod 51 has a rear end portion 511 and a front end portion 512 opposite to the rear end portion 511, and the front end portions 512 are integrally connected. It should be noted that the material of the braided bundle 50 may also be glass fiber, very fine metal wire, or a composite mixed braided material of metal wire and glass fiber.

Step 702, cutting off the front end portion 512 of the braided bundle 50, cutting off the rear end portion 511 and the separated front end portion 512 of the braided bundle 50 into strips, and simultaneously cutting off excess carbon fiber yarns to completely coat and impregnate the carbon fiber yarns with resin, thereby avoiding poor glue injection caused by too high density of local carbon fiber yarns.

Step 703, referring to fig. 7, in this embodiment, the auxiliary mold 91 is a wax product and includes a proximal arch surface 911 and a proximal body surface 912 opposite to the proximal arch surface 911, the braided bundle 50 is abutted against the proximal arch surface 911 of the auxiliary mold 91 and is bent toward the proximal body surface 912 so that the rear end portion 511 and the front end portion 512 protrude to the proximal body surface 912.

In step 704, referring to fig. 8, the forming mold 92 includes an upper mold part 921, a lower mold part 922 having a groove 924, and an injection hole 923 communicating with the groove 924, and the braided bundle 50 and the auxiliary mold 91 are turned over so that the braided bundle 50 is placed downward between the groove 924 and the auxiliary mold 91.

Step 705, the fiber cloth 41 is stacked in different fiber arrangement directions and is disposed downward on the near body surface 912, and covers and contacts the rear end portion 511 and the front end portion 512. In this embodiment, the number of the fiber cloths 41 may be plural, but the number is preferably four. It should be noted that the material of the fiber cloth 41 may also be glass fiber or very fine metal wire.

In step 706, referring to fig. 9, the upper mold part 921 is downwardly engaged with the lower mold part 922, and mold closing is completed.

In step 707, resin is injected through the injection hole 923 to fill the inside of the molding die 92 with the resin, so that the woven bundle 50 and the fiber cloth 41 are impregnated with the resin.

Step 708, heating the forming mold 92 to a temperature range to cure the resin coating the braided bundle 50 and the fiber cloth 41, wherein the temperature range is between 80 ℃ and 140 ℃ in this embodiment, and the resin can be gradually cured by heating to the temperature range.

Step 709, separating the upper mold part 921 and the lower mold part 922, and taking out the auxiliary mold 91 and the composite fiber seat cushion 3 from the groove 924 of the lower mold part 922.

Step 710, removing the auxiliary mold 91 attached to the composite fiber seat cushion 3 from the removed auxiliary mold 91 and the composite fiber seat cushion 3, and obtaining a finished product of the composite fiber seat cushion 3. In this embodiment, the auxiliary mold 91 is a wax product, and the auxiliary mold 91 is melted by heating and the residual wax attached to the composite fiber seat cushion 3 is scraped off to obtain a finished product of the composite fiber seat cushion 3. It is worth mentioning that the auxiliary mold 91 can also be made of plastic material, such as: the auxiliary mold 91 made of Expanded Polystyrene (EPS), expanded polypropylene (EPP), expanded polystyrene polyethylene (EPO), or a composite material of low melting point Alloy (Fusible Alloy) may be cut and removed by a tool, so as to obtain a finished product of the composite fiber seat cushion 3.

As described above, in the composite fiber seat cushion 3 and the method of manufacturing the same according to the present invention, the auxiliary mold 91 bends the knitted bundle 50 to a shape corresponding to the auxiliary mold 91, the fiber cloth 41 is overlapped and covers the other surface of the auxiliary mold 91, the fiber cloth 41 and the knitted bundle 50 are made to have an appearance close to the original shape of the seat cushion, the knitted bundle 50, the auxiliary mold 91 and the fiber cloth 41 are pushed into the molding mold 92 together, and resin is injected and heated, so that the knitted bundle 50 and the fiber cloth 41 are impregnated with resin and cured by heating, and thus a composite fiber seat cushion 3 having high breaking strength is manufactured in a simple process, and thus the object of the present invention can be achieved reliably.

The above description is only an example of the present invention, and the scope of the present invention should not be limited thereby, and the invention is still within the scope of the present invention by simple equivalent changes and modifications made according to the claims and the contents of the specification.