JP2000107472A - Manufacture of seat cushion and molding die used therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve working efficiency, reduce cost and improve position accuracy of holes by molding a cushion provided with a variety of holes in one process. SOLUTION: A method of manufacturing a seat cushion in which a cushion 10 which requires a variety of holes when forming a seat, by filling a mold with a textile elastic object and compressing, and during the compression of the textile elastic object in the mold, compression is performed while boring the textile elastic object in the parts of the cushion 10 to be bored.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushion body (pad) by filling and compressing a fibrous elastic body in a mold.
And a molding die used therefor.

[0002]

2. Description of the Related Art In addition to the method of compressing a fibrous elastic body in a molding die as described above, a foaming method of foaming urethane foam is mainly used for molding a cushion body in an automobile seat. It is necessary to machine a hole for attaching a skin material to the cushion body, or a hole for attaching a headrest in a cushion body for a seat back. In the above-mentioned foam molding method, it is easy to form holes at the same time as the cushion body is formed. However, in the compression molding method of the fibrous elastic body, it is difficult to form the holes at the same time as the cushion body. So in this case,
Drilling is performed by secondary processing after forming the cushion body.

FIG. 4 is an explanatory view showing a hole making step by a conventional secondary working. According to this secondary processing, FIG.
The cushion body 50 compression-molded as shown in FIG. 4A is placed on a support 54 shown in FIG.
(Or Thomson blade). Thereby, a part of the cushion body 50 is punched out as shown in FIG. 4C, and a hole 52 as shown in FIG. 4D is formed.

When an arc-shaped chamfer is required at the edge of the hole 52, first, at the time of compression molding of the cushion body 50, as shown in FIG.
As shown in FIG. 5A, a chamfered portion 53 is formed on the cushion body 50, and holes 52 are formed in the subsequent secondary processing as shown in FIG. 5B. Conversely, after the hole 52 is made in the cushion body 50, the chamfered portion 53 is processed by reforming.

[0005]

In the prior art, since the hole 52 is formed in the cushion body 50 by the secondary processing, the working efficiency is poor and the cost is increased. Then, the punch 56 compresses the cushion body 50 and
2 is punched out, so that the inner wall surface has a shape bulging inward as shown in FIG. Since the secondary processing is performed, the positional accuracy of the hole 52 with respect to the cushion body 50 is hardly obtained, and some countermeasures are required.

Further, as shown in FIG. 5A, when a kind of bottomed hole (recess) having a chamfered portion 53 is compression-molded in the cushion body 50, compression molding by a molding die is not sufficiently performed. There is a problem. That is, the bottomed hole having the chamfered portion 53 needs to be formed in consideration of the elastic recovery after the cushion body 50 is formed. However, even with such considerations, it is difficult to perform compression molding into a satisfactory shape as designed by the conventional method, and consequently the chamfered portion 53 is not sufficiently molded as originally intended. Become.

One object of the present invention is to improve the workability and reduce the cost by molding a cushion body having various holes in one step by one step. The purpose is to improve the positioning accuracy of the holes.

Another object of the present invention is to improve the shape of the hole and the finished state of the inner wall surface. Still another object of the present invention is to achieve a good finished state without causing underfill or the like even when forming a bottomed hole.

[0009]

Means for Solving the Problems The present invention has been made to achieve the above object, and the invention according to claim 1 is a method for forming a cushion which requires various holes in forming a seat. A method of manufacturing a seat cushion in which a fibrous elastic body is filled and compressed by filling the fibrous elastic body, wherein at the time of compressing the fibrous elastic body in the molding die, a portion of the fibrous elastic body where a hole is to be formed in the cushion body It is characterized in that it is compressed while making holes. The perforating process for the fibrous elastic body includes fusing the fibrous elastic body by the heat of the heating element or cutting the fibrous elastic body by a punch or a Thomson blade.

[0010] Thus, since the hole is formed simultaneously with the formation of the cushion body, the cushion body having various holes can be formed in one step, so that the workability can be improved and the cost can be reduced. In addition, unlike hole making by secondary processing after the cushion body is formed, the positional accuracy of the hole with respect to the cushion body is improved.

According to a second aspect of the present invention, there is provided a molding die used in the method of manufacturing a sheet according to the first aspect, wherein the fibrous elastic body is cut off by heat generated at a location corresponding to a hole to be opened in the cushion body. A heating element capable of performing the following operations is provided.

According to the first aspect of the present invention, the mold is used.
The described invention can be easily carried out, and furthermore, by performing perforation processing by fusing the fibrous elastic body by heat of the heating element, the shape of the hole and its inner wall surface can be finished finely.

According to a third aspect of the present invention, there is provided the mold according to the second aspect, further comprising a convex molding surface for molding a bottomed hole in the cushion body, and a fiber near the top surface. A heating element capable of fusing the elastic body is provided.

With the convex shaped surface, the bottomed hole is formed while the fibrous elastic body is blown off by the heating element provided in the vicinity of the top surface. The compression resistance of the added fiber elastic body is suppressed, so that the periphery of the hole can be effectively compressed. As a result, it is possible to prevent the occurrence of underfill or the like, which is likely to occur around the edge of the bottomed hole.

[0015]

Embodiments of the present invention will be described below. Embodiment 1 FIG. 1 is a perspective view showing a pad of a seat back in an automobile seat. As is clear from this drawing, the cushion body 10 (pad) is provided with the mounting hole 1 for the seat cover material.
2, a headrest mounting hole 13 and a seat belt mounting hole 14 are provided. In addition to the various mounting holes 12, 13, and 14, the cushion body 10 also has a groove 16 for disposing a suspension wire and the like for fixing the cushion body 10 to a seat frame (not shown).

FIG. 2 is an explanatory view showing a step of forming the cushion body 10. The cushion body 10 is formed by heating a fiber elastic body 40 such as polyester in a state of being compressed in the mold 20. The fibrous elastic body 40 is a mixture of a fibrous matrix resin and a fibrous binder resin at a weight ratio of 7: 3. These resin materials are loosened in a defibration process and then mixed in a cotton blending process. You. The fibrous elastic body 40 in a state where the matrix resin and the binder resin are evenly and well mixed is shown in FIG.
As shown in (A), the inside of the molding die 20 is blown and filled.

The molding die 20 has a structure in which an upper die 22 and a lower die 28 are incorporated in a mold frame 38, and the upper mold 22 can be moved up and down along the inside of the mold frame 38. ing. Openings 24 and 30 that are open to the outside are formed in the respective central portions of the upper mold 22 and the lower mold 28. However, the opening 30 of the lower mold 28 can be connected to a pipe or the like that communicates with a supply source of hot air or steam. Further, on the molding surfaces of the upper mold 22 and the lower mold 28, a large number of ventilation holes 26 and 32 penetrating vertically are formed, respectively.

The respective molding surfaces of the upper mold 22 and the lower mold 28 have respective mounting holes 12,
A cutter 34 is provided at a position corresponding to a place where one of 13 and 14 is to be machined. Each of these cutters 34 is provided with a heating element 36 using a nichrome wire or the like at each cutting edge.
6 generates heat by the energization, and the heat allows the fiber elastic body 40 to be blown.

Next, the formation of the cushion body 10 will be described. First, as shown in FIG. 2 (A), a fibrous elastic body 40 in which a matrix resin and a binder resin are mixed is blown into the inside of a molding die 20 from a blowing port (not shown) to fill the inside. At this time, the upper mold 22 and the lower mold 28
By applying a suction force to one or both of the openings 24 and 30 in the above, a flow of air for efficiently filling the fibrous elastic body 40 can be created.

When the fibrous elastic body 40 is sufficiently filled in the mold 20, the upper mold 22 is lowered to compress the fibrous elastic body 40 as shown in FIG. 2 (B). Simultaneously with this compression, the heating element 36 of the cutter 34 generates heat, and the mounting holes 12, 13, 1
Then, the fibrous elastic body 40 at a location corresponding to any one of 4 is blown.

Thereafter, as shown in FIG.
0 through the opening 30 of the lower mold 28 (220 to
240 ° C) hot air or steam. The hot air or the like passes through the ventilation holes 32 of the lower mold 28 and heats the fibrous elastic body 40, and passes through the ventilation holes 26 of the upper mold 22 to the outside through the opening 24. Then, inside the molding die 20, the cushion body 10 is formed by compressing and heating the fiber elastic body 40, and the cushion body 10 is provided with, for example, mounting holes 12 as shown in FIG.

As described above, since the boring process is performed simultaneously with the formation of the cushion body 10, even the cushion body 10 such as a seat back which requires various mounting holes 12, 13, 14 as described above can be used. It can be formed in one step. In addition, since the fibrous elastic body 40 is heated after the perforating process is performed as described above, the inner wall surface of the hole is cleanly processed, and it is easy to cope with the case where the inner wall surface is slightly tapered. it can. Needless to say, the secondary processing for drilling the cushion body 10 is not required. However, even when the secondary processing other than the hole is required, the holes that are processed at the same time as the molding are removed. It can be used for positioning.

Second Embodiment FIG. 3 is an explanatory view showing a molding process according to a second embodiment.
This drawing shows an example in which a bottomed hole such as a concave portion or a groove is formed in the cushion body 10, and therefore, a convex portion 27 is formed on the molding surface of the upper mold 22 at a position where the hole is to be formed.
Are formed. A heating element 37 using a nichrome wire or the like is incorporated in the vicinity of the top surface of the projection 27.

Also in the second embodiment, FIG.
After filling the inside of the molding die 20 with the fibrous elastic body 40 as shown by, the upper die 22 is lowered to compress the fibrous elastic body 40 as shown in FIG. At the same time, the heating element 3
7 is heated, and the compression is continued while fusing the fibrous elastic body 40 at the portion compressed by the convex portion 27. Thereby, the compression resistance of the fiber elastic body 40 applied to the top surface of the convex portion 27 is reduced, and the fiber elastic body 40 can be uniformly compressed by the entire molding surface of the upper mold 22.

Then, as shown in FIG.
After heating the fibrous elastic body 40 by feeding hot air or the like into the inside, the cushion body 10 is taken out of the molding die 20. The cushion body 10 has a bottomed hole 15 as shown in FIG. 3 (D). Since the bottomed hole 15 is also compressed and formed by the convex portion 27 while being blown off by the heating element 37 as described above, the inner wall surface is processed finely. In addition, regardless of the presence of the protrusions 27 for forming the bottomed hole 15, the fibrous elastic body 40 is uniformly compressed as described above, so that the periphery of the edge of the bottomed hole 15 is effectively formed. It is compressed and the occurrence of underfill or the like at this location can be prevented.

[0026]

According to the present invention, a cushion body having various holes can be formed in one step, so that the working efficiency can be improved, the cost can be reduced, and the shape of the holes and the inner wall surface thereof can be reduced. It is possible to improve the finished state and the positional accuracy of the holes. Further, even when a bottomed hole is formed in the cushion body, the periphery of the hole can be effectively compressed, and the occurrence of underfill around the edge can be prevented.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a pad of an automobile seat.

FIG. 2 is an explanatory view showing a step of forming a cushion body.

FIG. 3 is an explanatory view showing a molding step of the cushion body according to the second embodiment.

FIG. 4 is an explanatory view showing a hole making step by conventional secondary processing.

FIG. 5 is an explanatory view showing a conventional process for processing a hole whose edge is chamfered.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Cushion body 12,13,14 Mounting hole 20 Mold 36,37 Heating element 40 Fiber elastic body

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Takayasu Mori 25, Ueikeike, Yoshiwara-cho, Toyota-shi, Aichi Pref. F-term in Osaka Research Center Co., Ltd. (reference) 3B096 AD07

Claims (3)

[Claims] 1. A seat cushion manufacturing method for molding a cushion body which requires various holes in forming a seat by filling a molding die with a fibrous elastic body and compressing the same. A method for manufacturing a seat cushion, comprising, when compressing a fiber elastic body in a mold, performing compression while performing a perforating process on a portion of the fiber elastic body where a hole is to be formed in the cushion body. 2. A molding die used in the method for producing a sheet according to claim 1, wherein a heating element capable of fusing the fibrous elastic body by heat generation is provided at a position corresponding to a hole to be drilled in the cushion body. A molding die characterized by being provided. 3. The molding die according to claim 2, further comprising a convex molding surface for molding a bottomed hole in the cushion body, and capable of fusing the fiber elastic body near the top surface. A molding die characterized by having a heating element.