JPS6064810A - Manufacture of integral foamed and molded item - Google Patents

Abstract

PURPOSE:To integrally mold a foamed and hardened layer of a foaming material even at the corners of a cover material, by molding a cover material in a mold, allowing baffle plates to be raised by the foaming of a foaming material to be filled into the cover material thereby guiding the foamed stream of the foaming material to the corners of the cover material. CONSTITUTION:Stays 2 are stood and supported by brackets 7b, 7c, and baffle plates 5 that have been fitted loosely and supported previously on their axes are raised near a headrest frame 2a by slide pins 7d, 7e. Then a parison is extruded cylindrically from a die head with the lower side open, and is arranged on a base table 6c in such a manner that it receives the headrest frame 2a and stays 2 thereinto. Thereafter, the parison is clamped and secured between split molds 6a, 6b. After the clamping and securing the split molds 6a, 6b, compressed air is supplied into the parison via a valve 7a of the base table 6c to form a cover material 1 having a prescribed three-dimensional configuration. Thereafter, the cover material 1 is removed from the mold 6, and foaming material 8 is filled thereinto.

Description

TECHNICAL FIELD The present invention relates to a method of manufacturing an integrally foamed molded product, such as a headrest, in which a butt part is integrally foamed inside of a member such as a headrest.

BACKGROUND ART Conventionally, when manufacturing headrests, etc., for example,
A headrest cover is blow molded from the parison, and during the blow molding, the upper end of the stay shaft is inserted into the parin in advance, and after blow molding, the butt part is formed by foam hardening of the foam material filled into the headrest cover. By fixing the upper end of the shaft of the stay at the punt part, a headrest cover and a butt part are integrated to form a headrest with the stay protruding. However,
In that headrest, when the volume is increased by foam material or foaming, the air that was pushed into the cover by the foaming near the corners of the cover and the foaming gas that was not captured by the foam material remain on the foamed surface. This tends to cause the product to harden, resulting in the creation of a hollow portion where no punt portion exists, which can significantly impair commercial value.

In order to solve this problem, the present applicant fixedly attached a baffle plate to an axial line member such as a stay that was inserted in advance into a cover member to be molded, and the baffle plate forced the foaming flow of the foam material. It was previously proposed (Japanese Patent Application No. 58-133514) that the force should be moved to the corner of one member. When making a part near the corner of a part a clamping line with a mold, the force/long part is pulled by the clamping clamp of the mold and comes into contact with the baffle plate. There is a risk of force/scratching the hem member at the corner edge.

DISCLOSURE OF THE INVENTION The present invention provides a method for manufacturing an integrally foamed molded product in which a foam flow of a foam material is moved and guided to a corner portion of a cover member without damaging the cover member with a baffle plate. ,With the goal.

That is, in the method for manufacturing an integrally foamed molded product according to the present invention, a baffle plate is loosely fitted and supported on an axis member such as a frame that is inserted in advance into a cover member to be molded, and the cover member is clamped with the mold. When doing this, the force/< A baffle plate is placed at a distance from the parting line of the mold that holds the cover part, and after the cover part is molded, it is blocked by A on the foaming of the foam material to be filled into the cover part. By pushing up the plate toward the corner of the cover member and using the baffle plate to move and guide the foaming flow of the foam material to the corner of the cover member, the foam material can be reliably formed even at the corner. The foamed hardened layer can be integrally molded.

Embodiments will be described in detail below with reference to the drawings.

In the illustrated embodiment, for example, a substantially horseshoe-shaped headrest having a cavity in the center is manufactured as an integrally foamed product. In this headrest, a gap 4' where the butt part 4 does not exist is likely to be formed at a corner 3a near the rectangular end face of the rising part 3 where the stay 2 protrudes from the cover member l. A baffle plate 5 with a corresponding cross-sectional shape is loosely fitted and supported on the axis of the stay 2, and the baffle plate 5 forcibly moves and guides the foaming flow of the foam material to the corner portion as described later. 4′
(See Figure 1-2).

As the baffle plate 5, a hard resin plate or a metal plate can be used, or a porous plate material is impregnated with the foam material and finally cured integrally with the butt part.
It is also possible to use a flexible one. The baffle plate 5 is provided with collar portions 5a, 5b that protrude vertically at the openings into which the shaft member 2, such as a stay, is loosely inserted.
5b functions to maintain the distance between the cover member 1 and the cover member 1 as the foam material expands, which will be described later, no matter which one is used. In addition, a plurality of protrusions 5c, 5c, etc. are arranged at arbitrary intervals on the periphery of the baffle plate 5, and when the foam material is raised by pushing up the foam, contact with the cover member l is prevented from clogging, and the ascent is facilitated. (See Figure 3).

Blow molding can be applied to mold the headrest. The blow molding mold 6 has split molds 8 on the left and right.
a, 8b, and a base 6C on which the split molds 8a, Bb are placed facing each other. The base 6C is equipped with a valve 7111 discharging compressed air at the center, and bladders 7b and 7c are provided on the left and right sides of the valve 7111 for installing the stay 2 integrated with the headrest frame 2a, and further on the axis of the stay 2. The slide bin 7d that pushes up the baffle plate 5 which is loosely fitted and supported on the ? e (see Figure 4).

Using this mold 6, first make the stay 2 into a bracket) 7b.
, 7c to support the standing position, and push the baffle plate 5, which has been previously supported on each axis 1-, to the vicinity of the headrest frame 2a using slide bins 7d and 7e. Next, the parison forming the cover member 1 is extruded from the tie held into a cylinder with its lower end open, and placed on the base 6C so that the headrest frame 2a and the stay 2 are received inside the parison. After that, the parison is clamped and fixed between the split molds 8a and 8b, but at this time, the lower end of the parison is bent to form a raised part 3 from which the stay 2 of the dress rest is projected, and the split molds 6a and eb In order to form a parting line on the edge side of the parting line, the baffle plate 5 is kept supported upward by the slide bins 7d and 7e in order to separate the baffle plate 5 from the parting line. If the split molds Ba and 8b are clamped in this state, even if the parison forming the cover member 1 is displaced due to tension, it will not come into contact with the baffle plate 5.

After the mold 6 is clamped and fixed, compressed air is supplied into the parison from the valve 7a of the base 6C to mold the cover member l having a desired three-dimensional shape. Thereafter, the cover member 1 molded into a three-dimensional shape is removed from the mold 6, and the inside is filled with the foam material 8. When the foam material 8 is filled, the cover member 1 is inverted so that the stay 2 protrudes upward so that the foam material 8 stays inside the top of the cover member L (see Fig. 5). Material 8 is heated and foamed. With this heating and foaming, the foam material 8 gradually increases in volume and rises, pushing the baffle plate 5 located near the headrest frame 2a of the stay 2 upward along the axis of the stay 2.
Move up and down (see Figure 6). The baffle plate 5 that is pushed up further rises within the rising portion 3 of the headrest, and when the collar portion 5a comes into contact with the end surface forming the corner portion 3a, it stops rising 7, and continues to increase in volume. A foaming flow of a certain foam material is guided by flowing from the edge to the back side along the plate surface of the baffle plate 5. During the guidance, the foaming flow of the foam material rapidly moves through the gap between the cover member l and the edge of the baffle plate 5, so that the foam material is moved to the corner portion 3 of the cover member l.
a, and at the same time, the debris can be dissipated from the air vent hole 1a of the cover member 1. The gap that causes this foam material flow should be set to about 3 to 5 cm.
By appropriately setting the area of the baffle plate 5 in accordance with the cross-sectional area of the rising portion 3, a desired gap can be provided (
(See Figure 7).

In the above-described embodiment, the baffle plate 5 is inserted in advance when the cover member 1 is molded, but it may be attached to the shaft line member such as the stay 2 after the cover member 1 is molded. Further, although this embodiment shows a headrest having rising portions 3 corresponding to the left and right stays, the present invention can also be applied to molding a headrest having a general trapezoidal shape. In that case, one baffle plate is loosely fitted and supported between the stays, and the foaming flow of the foam material can be moved and guided to each corner of the square. Furthermore, it is applicable not only to the production of headrests but also to the production of various foam molded products, and the members that loosely fit and support the baffle plate 5 are not limited to those protruding from the cover member 1 such as stays. A frame embedded in a foam material can also be used.

In this way, by foaming and hardening the foam material, it is possible to integrally mold the butt part 4 which is completely filled inside the cover member l.

Effects of the Invention According to the method for manufacturing an integrally foamed molded product according to the present invention, it is possible to integrally mold a butt portion without a void inside the cover member without damaging the cover member with the baffle plate. It becomes like this.

[Brief explanation of the drawing]

＠Figure i is a perspective view showing a headrest as an example of the integrally foamed molded product manufactured by the present invention, Figure 2 is an explanatory diagram showing problems in manufacturing the same headrest, and Figure 3 is a diagram showing the obstacles used in the method according to the present invention. A perspective view of the plate, FIG. 4 is an explanatory diagram of the mold used in the same method, FIG. 5 is an explanatory diagram of the cover member filled with the foam material after molding, and FIGS. In the figure,
1 is a partially enlarged side view showing the foaming flow of the foam material. 1: Cover member, 2 Axis member such as Nisty, 3a: Corner, 5: Baffle plate, 6: Mold, 8: Fort material.

Claims (1)

[Claims] A baffle plate is fitted and supported on an axial member such as a frame that is inserted in advance into a cover member to be molded, and when the cover member is clamped, it is removed from the parting line where the cover member of the mold is clamped. The plates are placed in a separate position, and after the cover member is formed with a mold, the foam material filled in the cover member expands and moves the baffle plate upward toward the open corner of the cover member, and the baffle plate moves the foam material. 1. A method for producing an integrally foamed molded product, characterized in that the foaming flow is guided to move to a corner portion of a cover member.