Particle foam component having a textured surface and method and mold for the manufacture thereof
AssigneeHerman Miller, Inc.
InventorsJANJA MAIDL, CLAUDIA PLIKAT, JOHANN BURKHARD SCHMITZ, ROLAND ROLF OTTO ZWICK, CAROLA EVA MARIANNE ZWICK
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Abstract
An element molded from a particle foam, including for example expanded polypropylene foam, includes at least one visible exterior surface defined by the particle foam. The visible exterior surface is textured having a roughness depth of less than or equal to 1.00 mm and a plurality of vent interfaces each having a maximum width of less than or equal to 0.4 mm. Methods of molding the element, together with a mold and a method of making the mold, are also provided.
Claims21
A molded component comprising:
- an element molded from a particle foam, said element comprising at least one visible exterior surface defined by said particle foam, wherein said visible exterior surface is textured having a roughness depth of less than or equal to 1.0 mm and a plurality of vent interfaces each having a maximum width of less than or equal to 0.4 mm.
A method of molding a component comprising:
- introducing beads of particle foam into a mold interior, wherein said mold comprises at least one textured molding surface defining at least in part said mold interior, wherein said molding surface comprises a roughness depth of less than or equal to 0.5 mm and a plurality of vents each having a maximum width of less than or equal to 0.4 mm
- introducing steam into said mold interior through said plurality of vents for a predetermined period of time;
- fusing said beads of particle foam with said steam and thereby forming a molded element;
- and
- removing said molded element from said mold.
14-45. (canceled)
A method of molding a component comprising:
- pressure filling beads of a particle foam into a mold interior defined by a mold, wherein said mold comprises at least one textured molding surface defining at least in part said mold interior, wherein said molding surface comprises a plurality of vents on opposite sides of said mold interior, said plurality of vents each having a maximum width of less than or equal to 0.4 mm;
- moving steam through said mold interior in a first flow direction through said plurality of vents for a first predetermined period of time;
- moving steam through said mold interior in a second flow direction opposite said first direction through said plurality of vents for a second predetermined period of time;
- introducing steam to said mold interior from said first and second directions for a third predetermined period of time, wherein said third predetermined period of time is greater than said first and second predetermined periods of time;
- water cooling said mold;
- air cooling said mold;
- and
- removing a molded element from said mold.
Dependencies are inferred from the claim text.