Manufacturing method for a car safety seat

Abstract

A manufacturing method for a car safety seat includes the following steps: providing a mold and disposing a main body of the car safety seat into the mold, and injecting a foam material into a cavity of the mold and foaming the foam material so as to form a flexible layer integrated with the main body. A pressure in the cavity is between 1.5 bar and 5.0 bar. The manufacturing method disposes the main body into the mold and directly forms a flexible layer on the main body, so that the flexible layer ensures safety and comfort of the car safety seat while saves the necessity to dispose a seat pad or a cushion and fixing structures on the main body, and thereby reduces the cost and the work-hour of assembly, and the overall weight of the car safety seat can be reduced by omitting the fixing structures.

Claims

1. A manufacturing method for a car safety seat, the manufacturing method comprising: providing a mold and disposing a main body of the car safety seat into the mold; injecting a foam material into a cavity of the mold and foaming the foam material in the cavity of the mold so as to form a flexible layer integrated with the main body, wherein a pressure in the cavity of the mold is between 1.5 bar and 5.0 bar during a foaming process; drawing the car safety seat from the mold; disposing at least one fixing fixture into at least one hollow structure of the main body after drawing the car safety seat from the mold; drying the car safety seat after disposing the at least one fixing fixture into the at least one hollow structure of the main body; and removing the at least one fixing fixture from the main body after the car safety seat is shaped.

2. The manufacturing method of claim 1, wherein the pressure in the cavity is between 2.0 bar and 4.0 bar during the foaming process.

3. The manufacturing method of claim 1, wherein an average particle diameter of the foam material after being foamed is between 1 mm and 10 mm.

4. The manufacturing method of claim 1, wherein a wall thickness of the main body is substantially 1.5 mm.

5. The manufacturing method of claim 1, further comprising: injecting a vapor into the cavity of the mold after injecting the foam material into the cavity, for combining the foam material with the main body by temperature and the pressure.

6. The manufacturing method of claim 1, further comprising: cooling the formed flexible layer; and demolding the mold to draw the car safety seat comprising the main body and the flexible layer manually or by an ejector pin.

7. The manufacturing method of claim 6, further comprising: cooling the car safety seat after drawing the car safety seat from the mold.

8. The manufacturing method of claim 7, further comprising: deburring the car safety seat after cooling the car safety seat.

9. The manufacturing method of claim 1, further comprising: disposing a sealing fixture onto the main body of the car safety seat to temporarily seal at least one hole or at least one groove on the main body of the car safety seat before disposing the main body of the car safety seat into the mold.

10. A manufacturing method for a car safety seat, the manufacturing method comprising: providing a mold and disposing a main body of the car safety seat into the mold; injecting a foam material into a cavity of the mold and foaming the foam material in the cavity of the mold so as to form a flexible layer integrated with the main body; drawing the car safety seat from the mold; disposing at least one fixing fixture into at least one hollow structure of the main body after drawing the car safety seat from the mold; drying the car safety seat after disposing the at least one fixing fixture into the at least one hollow structure of the main body; and removing the at least one fixing fixture from the main body after the car safety seat is shaped.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a main flow diagram illustrating a manufacturing method of a car safety seat according to an embodiment of the present application.

(2) FIG. 2 is a diagram of a car safety seat manufactured by the manufacturing method according to the embodiment of the present application.

(3) FIG. 3 is a more detailed flow diagram illustrating the manufacturing method of the car safety seat according to the embodiment of the present application.

DETAILED DESCRIPTION

(4) In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” etc., is used with reference to the orientation of the Figure (s) being described. The components of the present invention can be positioned in a number of different orientations. As such, the directional terminology is used for purposes of illustration and is in no way limiting. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.

(5) Please refer to FIG. 1 and FIG. 2. FIG. 1 is a main flow diagram illustrating a manufacturing method of a car safety seat 1 according to an embodiment of the present application. FIG. 2 is a diagram of the car safety seat 1 manufactured by the manufacturing method according to the embodiment of the present application. The present application provides the manufacturing method for post forming a shaped polypropylene (PP) main body 11 for producing the car safety seat 1, without a need to dispose a seat pad or a cushion onto the main body 11. The manufacturing method includes two main steps of providing a mold and disposing the main body 11 into the mold before closing the mold, and injecting a foam material into a cavity of the mold and foaming the foam material in the cavity of the mold to form a flexible layer 12 covering and integrated with the main body 11.

(6) After the foam material is injected into the cavity of the mold, a vapor is injected with high temperature into the cavity to provide the cavity with a particular environment of temperature and pressure. The foam material is foamed and combined with the main body 11 under the temperature and the pressure. The pressure in the cavity during the foaming process can be set between 1.5 bar and 5.0 bar, preferably can be set between 2.0 bar and 4.0 bar. After the foaming and post forming process, the car safety seat 1 can be kept and cooled in the cavity for a certain period before being drawn out of the mold. A wall thickness of the main body 11 can be substantially 1.5 mm. It should be noticed that a clearance between the main body 11 and an inner wall of the mold can be restricted to avoid deformation of the main body 11.

(7) During the foaming process, four important conditions of the process are pressure, vapor temperature, foam expansion ratio, and cooling time. By adjusting the conditions, nine different foamed specimens are produced as shown in the following table:

(8) TABLE-US-00001 Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Sample 6 Sample 7 Sample 8 Sample 9 Process Pressure 3.5 3.5 3.5 2 4 1.5 5 1 6 conditions (bar) Vapor 125 125 125 125 125 110 150 100 170 temperature (° C.) Foam 45 30 50 45 45 45 45 expansion ratio Cooling time 55 55 55 55 55 55 55 55 55 (sec.) quality of the excellent excellent excellent good good fair fair Failed Shrunk by formed sample to foam overheating Average particle 6 1 10 6 6 6 6 diameter (mm)

(9) It can be concluded from the above table that the foam material is unable to foam if the pressure in the cavity is too low (lower than 1.5 bar, specifically). While the foam material overly foams when the pressure in the cavity is too high (higher than 6 bar, specifically), the foam particles shrink and the main body 11 deforms due to excessive pressurization. Therefore, the present application limits the pressure between 1.5 bar and 5.0 bar, and preferably between 2.0 bar and 4.0 bar.

(10) Furthermore, quality of the formed car safety seat 1 is affected by the parameters of the foam expansion ratio and the average particle diameter of the foam material. A final product of the car safety seat 1 might have overweight if the foam expansion ratio is substantially lower than 30, while an otherwise lightweight product has poor impact resistance if the foam expansion ratio is substantially higher than 50. The average particle diameter of the foam material can be designed between 1 mm and 10 mm for producing a lightweight car safety seat 1, and the average particle diameter is defined as an average value of measured diameters of all the foam particles within a 1 cm.sup.3 volume. Specifically, the foam material of the embodiment can be expanded polypropylene (EPP).

(11) Please refer to FIG. 3. FIG. 3 is a more detailed flow diagram illustrating the manufacturing method of the car safety seat 1 according to the embodiment of the present application. The detailed manufacturing method for the car safety seat 1 includes the following steps:

(12) Providing the mold and disposing the main body 11 into the mold, and then closing the mold;

(13) Injecting the foam material into the cavity of the mold;

(14) Injecting the vapor with high temperature into the mold to provide an environment of particular temperature and pressure to combine the foam material with the main body 11, so as to form the flexible layer 12 covering the main body 11;

(15) Cooling the formed flexible layer;

(16) Demolding the mold to draw the car safety seat 1 manually or by an ejector pin;

(17) Drying and cooling the car safety seat 1; and

(18) Deburring the car safety seat 1.

(19) After finishing the manufacturing method for the car safety seat 1, the car safety seat 1 is ready to be packaged.

(20) There are many holes or grooves on the main body 11, and the holes or the grooves may be filled by the foam material during the foaming process if the main body 11 is directly put into the mold for the foaming process. Therefore, sealing fixtures can be utilized to be disposed on the main body 11 for temporarily sealing the desirable holes or grooves in advance before the main body 11 is put into the mold for the foaming process, so as to prevent the desirable holes or grooves from being filled by the foam material. The sealing fixtures can be plugs having shapes corresponding to the shapes of the holes or grooves.

(21) The demolded car safety seat might be deformed by heat in the step of drying, and hollow structures on the main body 11, such as holes, grooves, or trenches, are particularly easy to be deformed. Therefore, fixing fixtures can be utilized to be inserted in to the hollow structures to keep shapes of the hollow structures before the car safety seat is dried through the drying process. During the drying process, possible deformation is avoided as the fixing fixtures holds at these locations of the hollow structures to fix the shapes thereof. The fixing fixtures can be plugs having shapes corresponding to the shapes of the hollow structures.

(22) In contrast to the prior art, the manufacturing method of the present application disposes the main body 11 into the mold and directly forms the flexible layer 12 on the main body 11 by the foaming process. The flexible layer 12 ensures the safety and comfort of the car safety seat 1 and saves the necessity to dispose a seat pad or a cushion and fixing structures on the main body 11. Therefore, the present application can achieve the purposes of reducing the cost and the work-hour of assembly. The overall weight of the car safety seat 1 is also reduced since the fixing structures are omitted.

(23) Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.