Seat-back frame, method for preparing the same, and seat-back for vehicle

Patent metadata

Field	Value
Publication number	US-10118523-B2
Application number	US-201515328848-A
Country	US
Kind code	B2
Filing date	Sep 24, 2015
Priority date	Sep 24, 2014
Publication date	Nov 6, 2018
Grant date	Nov 6, 2018

Abstract

A seatback frame includes: a body frame comprising a long fiber reinforced thermoplastic (LFT) composite material; and an inner frame comprising a continuous fiber reinforced thermoplastic (CFT) composite material buried in the body frame by insert injection-molding. A method for manufacturing the same, and a seatback for vehicles including the same are also disclosed.

First claim

The invention claimed is:

1. A seatback frame comprising:
a body frame comprising a long fiber-reinforced thermoplastic (LFT) resin composite material, the long fiber-reinforced thermoplastic resin composite material comprising a thermoplastic resin and a reinforcing long fiber; and
an inner frame comprising a continuous fiber-reinforced thermoplastic (CFT) resin composite material buried in the body frame by insert injection-molding, the continuous fiber-reinforced thermoplastic resin composite material comprising a thermoplastic resin and a reinforcing continuous fiber,
wherein
the inner frame is formed in advance by press-molding to implement a predetermined shape,
the long fiber-reinforced thermoplastic resin composite material contains 30% by weight to 40% by weight of the reinforcing long fibers having a length from 50 mm to 100 mm,
the continuous fiber-reinforced thermoplastic resin composite material contains 60% by weight to 70% by weight of the reinforcing continuous fibers having a length of 10 cm or more,
the continuous fiber-reinforced thermoplastic resin composite material has a tensile strength of 300 MPa to 600 MPa according to ASTM D638 standard specification, and a bending strength of 350 MPa to 500 MPa according to ASTM D790 standard specification,
the long fiber-reinforced thermoplastic resin composite material has a tensile strength of 100 MPa to 120 MPa according to ASTM D638 standard specification, and a bending strength of 100 MPa to 200 MPa according to ASTM D790 standard specification.

2. The seatback frame according to claim 1 , wherein the thermoplastic resin included in the long fiber-reinforced thermoplastic resin composite material or the continuous fiber-reinforced thermoplastic resin composite material comprises at least one selected from a group consisting of a polypropylene resin, a polyethylene resin, a polyamide resin, a polyester resin, a polyphenylene sulfide resin and a combination thereof.

3. The seatback frame according to claim 1 , wherein the reinforcing long fiber and/or the reinforcing continuous fiber comprises at least one selected from a group consisting of glass fiber, aramid fiber, natural fiber, polyester fiber, polyamide fiber and a combination thereof.

4. The seatback frame according to claim 1 , further comprising:
an armrest frame,
wherein the body frame and the armrest frame are integrally molded.

5. A seatback for vehicles comprising: the seatback frame according to claim 1 .

6. A method for manufacturing a seatback frame, the method comprising:
preparing an inner frame having a predetermined shape by forming a continuous fiber-reinforced thermoplastic (CFT) resin composite material in advance by press-molding, the long fiber-reinforced thermoplastic resin composite material comprising a thermoplastic resin and a reinforcing long fiber; and
inserting and injection-molding the inner frame into a long fiber-reinforced thermoplastic (LFT) resin composite material to manufacture a body frame having the inner frame buried therein, the continuous fiber-reinforced thermoplastic resin composite material comprising a thermoplastic resin and a reinforcing continuous fiber,
wherein
the long fiber-reinforced thermoplastic resin composite material contains 30% by weight to 40% by weight of the reinforcing long fibers having a length from 50 mm to 100 mm,
the long fiber-reinforced thermoplastic resin composite material has a tensile strength of 100 MPa to 120 MPa according to ASTM D638 standard specification, and a bending strength of 100 MPa to 200 MPa according to ASTM D790 standard specification,
the continuous fiber-reinforced thermoplastic resin composite material contains 60% by weight to 70% by weight of the reinforcing continuous fibers having a length of 10 cm or more, and
the continuous fiber-reinforced thermoplastic resin composite material has a tensile strength of 300 MPa to 600 MPa according to ASTM D638 standard specification, and a bending strength of 350 MPa to 500 MPa according to ASTM D790 standard specification.

7. The method according to claim 6 , wherein the press-molding is carried out at a temperature of 40° C. to 60° C.

8. The method according to claim 7 , wherein the press-molding is carried out at a pressure of 100,000 kgf/cm 2 to 300,000 kgf/cm 2 .

Assignees

• Lg Hausys Ltd

Inventors

• Song Kang-Hyun
• Kil Yong-Kil
• Lee Tae-Hwa
• Lee Kyung-Hoon
• Kim Hee-June

Classifications

• B29L2031/771

  Seats · CPC title

• B29C70/16

  using fibres of substantial or continuous length {(non-woven fabrics per se D04H3/00)} · CPC title

• B60N2/75

  Arm-rests · CPC title

• B29C45/14786

  Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material · CPC title

• B29D99/0092

  Producing upholstery articles, e.g. cushions, seats (B29C63/025 takes precedence) · CPC title