JP2002028895A - Manufacturing method for molding and molding manufactured by this method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method for a molding capable of obtaining the molding of the shape corresponding to dies by pressing a block-like material 3 into the dies to be elastically deformed, cutting it into a slice shape in this state, then removing external force. SOLUTION: The block-like cushion raw material 3 is compressed by the seat-shaped dies 1 and 2, the cushion raw material 3 is cut into the slice shape in this state, then external force is removed to obtain a cushion 3b of the shape corresponding to the dies 1 and 2.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a molded article from a rubber-like elastic material such as urethane foam and a molded article obtained by the method. For example, the present invention relates to a sheet for automobiles and motorcycles and a method for producing the same. Applicable.

[0002]

2. Description of the Related Art As shown in FIG. 7, a seat for an automobile or a motorcycle is mounted on a seat base material 102, and a cushion 103 made of leather or the like is placed on the cushion 101, as shown in FIG. The cushion 101 is covered with the skin material 103, the skin material 103 is wrapped around the sheet base 102 on the back side, and is stopped by the tucker 104 or the like to form the seat assembly 105. Cushion 1
01 is made by foaming each one by a foaming mold having the shape of the cushion 101.

As another method of manufacturing a sheet, as shown in FIG. 8, a plate 107 is prepared by slicing an industrially manufactured block-shaped urethane foam 106, and punching the plate 107 according to the shape of the sheet. Cushion 10
It is considered that the sheet assembly 105 is placed on the sheet base material 102, the skin material 103 is put on the sheet base material 102, the skin material 103 is wrapped around the sheet base material 102 on the back side, and is stopped by the tucker 104 or the like. Can be

[0004]

However, in the above-mentioned conventional method in which the cushion is foamed one by one with the foaming mold, foaming takes a long time and the production capacity per foaming mold is low (100 to 200). Per day). In this method, it is necessary to increase the number of molds (foaming molds) in order to increase the production amount, and this causes an increase in depreciation costs. In other words, it is necessary to invest in a mold corresponding to the maximum number of productions, which results in excessive depreciation costs.

[0005] Further, a block-like urethane foam 10
In the method of forming the plate 107 from 6 and punching it out into the cushion 108, the reaction force of the cushion 108 is large, and it is difficult to make the end of the cushion 108 follow the end of the curved sheet base material 102. The product obtained is also a cushion 10 as shown in FIG.
Since 8 was plate-shaped, the end was thick and the appearance was poor. In order to prevent such a problem, the plate 107
It is conceivable to cut the side surface and the surface according to the sheet shape, but the operation is troublesome and the yield is extremely deteriorated. Such a problem occurs not only in the seats of automobiles and motorcycles but also in seats of furniture and the like, and also in all molded products.

[0006] The present invention has been made in view of the above-mentioned conventional technical situation, and has high productivity and cost reduction.
An object of the present invention is to provide a method for producing a molded article and a molded article which can also improve the appearance. Further objects of the present invention will be apparent in the following description.

[0007]

According to the present invention, there is provided a method for manufacturing a molded article, which comprises the steps of: pressing a block-shaped material against a mold to elastically deform the material; cutting the material into slices in that state; By removing the molded product, a molded product having a shape corresponding to the mold is obtained. According to the method for manufacturing a molded product according to the present invention, the molded product cut into a slice is
When the external force is removed and the external force is restored, the shape becomes the same as that of the mold. Therefore, if the mold is formed in a concave shape such as a bowl shape,
The molded article also becomes concave by returning to the original state.

The molded product according to the present invention is obtained by pressing a block-shaped material against a mold to elastically deform the material, and then cutting the material into slices. Just cutting into slices will result in a molded product corresponding to the mold.

In the method of manufacturing a molded article according to the present invention, a block-shaped elastic material such as urethane foam is pressed against a mold to be elastically deformed, cut in a slice shape in that state, and removed from the mold by removing external force. It is characterized by obtaining a molded product of a corresponding shape. According to the method of manufacturing a molded product according to the present invention, a molded product made of an elastic material such as urethane foam cut into a slice has a shape similar to that of a mold when external force is removed and the molded product returns to its original shape.

[0010] In the method for manufacturing a cushion according to the present invention, a block-shaped cushion material is elastically deformed by pressing it against a sheet-shaped mold, and in that state, the cushion material is cut into slices to remove external force. It is characterized in that a cushion having a shape corresponding to the mold is obtained. According to the cushion manufacturing method of the present invention, the cushion material cut into a slice shape returns to its original shape after the external force is removed, thereby forming a cushion having a shape corresponding to the mold.

According to the method for producing a molded product according to the present invention,
The block-shaped material is elastically deformed by pressing it into a mold, cut in a slice shape in that state, and a shape corresponding to the mold is obtained by removing an external force, and further punched into a desired shape. According to the method for producing a molded article according to the present invention,
The material cut into slices has a shape corresponding to the mold when external force is removed, and has a desired shape when punched out.

According to the method of manufacturing a cushion according to the present invention, the cushion material is elastically deformed by pressing the cushion material against a sheet-shaped mold, and the cushion material is cut into slices in that state, and the external force is removed. It is characterized in that a cushion material corresponding to a mold is obtained, and a cushion is obtained by further punching. According to the method of manufacturing a cushion according to the present invention, the cushion material cut into slices becomes the cushion as it is. If necessary, the shape can be adjusted by punching.

According to the seat of the present invention, the cushion material is elastically deformed by pressing the cushion material against a mold having the shape of the seat, and the cushion material obtained by cutting the cushion material into slices and taking out the cushion material in this state. The cushion is covered with a skin material, and the edge of the skin material is fastened to the sheet base material. According to the sheet according to the present invention, since the sliced shape is in the form of a cushion as it is, the sheet can be easily obtained by placing it on the sheet base material and winding the skin material.

[0014]

An embodiment of the present invention will be described with reference to the drawings. 1 to 4 show a manufacturing method and a molded product according to an embodiment of a motorcycle seat.

In FIG. 1, reference numeral 1 denotes a first mold, and a mold portion 1a is formed on the inner surface thereof in a concave shape corresponding to the shape of a sheet to be manufactured. The second mold 2 is located facing the first mold 1. On the inner surface of the second mold 2, a convex mold part 2 a is formed corresponding to the mold part 1 a of the first mold 1. The two dies 1 and 2 are configured to be relatively close to each other. For example, the second mold 2 as the upper mold can be configured to move up and down with respect to the first mold 1 fixed as the lower mold, or the first mold 1 and the second mold 2 on the left and right approach each other. It may be possible to move away.

A block 3 of a sponge-like polyurethane foam, which is a raw material, is set between a first mold 1 and a second mold 2. This block material 3 is produced industrially.

In this state, the first mold 1 and the second mold 2 are moved closer to each other, and the block material 3 is compressed and elastically deformed as shown in FIG. In the figure, the alternate long and short dash line schematically shows how the structure of the block material 3 is deformed.

In this state, the block 3 is cut into slices by the rotating cutter 4. As shown in FIGS. 3 (b) and 4 (a), the cushion material 3a that has been cut and taken out is restored by the release of the external force, and has a shape opposite to the shape that has been compressed and deformed (a bowl shape). ). In other words, since the sheet is cut into a flat plate while being distorted by an external force, when the external force is removed and the strain is removed, the sheet is deformed in a direction opposite to the direction in which the strain was applied.

Since the cushion material 3a is rectangular when viewed from above, it is punched out by a press machine to
(c), a seat-shaped cushion 3 as shown in FIG.
b.

FIG. 4C shows a cross section of the sheet 8 as a product, and FIG. The cushion 3b obtained as described above is placed on the bottom plate 5, which is a sheet substrate. The bottom plate 5 is made of, for example, polypropylene by injection molding. A skin material 6 such as leather or polyvinyl chloride (PVC) is put on the cushion 3b. Then, the edge 6 a of the skin material 6 is wrapped around the back side of the bottom plate 5, where it is fixed to the bottom plate 5 by the tucker 7. 5, the cushion 3b is cut slightly larger (S) than the bottom plate 5. Thus, by slightly increasing the size, the roundness is obtained when the skin material 6 is stretched, and the appearance is improved.

FIG. 6 shows another embodiment. In this embodiment, a urethane foam block material 13 is used.
The cross-sectional shape forms the projected shape of the cushion. Therefore, the cushion 3 is cut directly into slices while being compressed by two molds.
b is obtained. The punching step is not required, and the yield is improved.

In the above embodiment, when the block material 3 or 13 is pressed and deformed by the dies 1 and 2, the sizes of the concave portions 1a and the convex portions 2b of the two dies 1 and 2 are determined.
That is, by changing the depth of the concave portion 1a and the height of the peak of the convex portion 2a, the degree of compression is made different depending on the location of the block material, and the product obtained when cut into slices has different thickness depending on the location. It can be concave. That is, for example, the thickness of the terminal portion can be gradually reduced.

In the above embodiment, the seat of a motorcycle is taken as an example. However, the molded article according to the present invention and the method of manufacturing the same are not limited to this. Is not limited. Also, the material is not limited to urethane foam, but can be applied to other rubber-like elastic materials.

[0024]

According to the method of manufacturing a molded article according to the present invention, the block-shaped material is elastically deformed by pressing it against the mold, and cut into slices in that state to remove the external force, thereby responding to the mold. Since a molded product having a predetermined shape is obtained, the productivity of the molded product is improved, and the cost is reduced. Also,
Since there is no need to have many molds, this also reduces costs. Of course, the burden of storing and repairing the mold is reduced.

The molded product according to the present invention is obtained by pressing a block-shaped material against a mold and elastically deforming the material, and cutting the material into slices in that state. Can also be planned.

In the method for producing a molded article according to the present invention, a block-shaped elastic material such as urethane foam is pressed against a mold to be elastically deformed, cut in a slice shape in that state, and the external force is removed. Since a molded article having a corresponding shape is obtained, a block material such as urethane foam which is industrially produced can be used as a raw material, thereby improving productivity and reducing costs. Since a product is obtained by cutting into slices, the production efficiency is improved, and this also leads to cost reduction.

In the method of manufacturing a cushion according to the present invention, the cushion material is elastically deformed by pressing it against a sheet-shaped mold, and the cushion material is cut into slices in that state, and the external force is removed to form the cushion material. Since a cushion having a corresponding shape is obtained, the productivity of the cushion can be improved and the cost can be reduced.

According to the method for producing a molded article according to the present invention,
The block-shaped material is elastically deformed by pressing it into a mold, cut into slices in that state, a shape corresponding to the mold is obtained by removing external force, and a molded product is obtained by punching into a desired shape. So, like before,
The productivity is significantly improved and the cost is reduced as compared with the case of molding or cutting out one by one mold.

According to the method of manufacturing a cushion according to the present invention, the block-shaped cushion material is pressed against a mold having the shape of a sheet to be elastically deformed, and in this state, the cushion material is cut into slices to remove external force. As a result, a cushion material corresponding to the mold is obtained, and the cushion material is punched to obtain a cushion, so that the productivity of the cushion is improved and the cost is reduced.

According to the seat of the present invention, the cushion material is pressed against the mold having the shape of the sheet to be elastically deformed, and the cushion obtained by cutting the cushion material into slices in this state is placed on the sheet substrate. The cushion is covered with a skin material, and the edge of the skin material is wound around the back side of the sheet base material to form a sheet, so that the time required for manufacturing the sheet can be reduced, and the man-hour can be reduced. And productivity can be improved and costs can be reduced.

[Brief description of the drawings]

FIG. 1 is a schematic view of one step (before compression) of a method for manufacturing a molded product according to an embodiment of the present invention.

FIG. 2 is a schematic view of one step (in a compressed state) of a method for manufacturing a molded product according to an embodiment of the present invention.

FIG. 3 is a perspective view showing steps of a method for manufacturing a molded product according to one embodiment of the present invention.

FIG. 4 is a cross-sectional view illustrating a process from a cushion material to a product according to an embodiment of the present invention.

FIG. 5 is a partially enlarged view of FIG. 4 (c).

FIG. 6 is a perspective view showing steps of a method for manufacturing a molded product according to another embodiment of the present invention.

FIG. 7 is a schematic view showing a conventional sheet manufacturing method.

FIG. 8 is a schematic view showing another conventional sheet manufacturing method.

[Explanation of symbols]

1: first mold, 2: second mold, 3: block material, 3
a: cushion material, 3b: cushion, 4: cutter
5: Bottom plate, 6: Skin material, 8: Sheet, 13: Block material

Claims (7)

[Claims] 1. A molding characterized in that a block-shaped material is pressed against a mold to be elastically deformed, cut into slices in that state, and a molded product having a shape corresponding to the mold is obtained by removing external force. Product manufacturing method. 2. A molded product obtained by pressing a block-shaped material against a mold to elastically deform the material, and then cutting the material into slices. 3. A block-shaped elastic material such as urethane foam is pressed against a mold to be elastically deformed, and cut into slices in that state to obtain a molded product having a shape corresponding to the mold by removing external force. A method for producing a molded article characterized by the following. 4. A block-shaped cushion material is elastically deformed by pressing it against a mold having a shape of a sheet. In this state, the cushion material is cut into slices, and an external force is removed to form the cushion material into a shape corresponding to the mold. A method for producing a cushion, characterized by obtaining a cushion. 5. A method in which a block-shaped material is pressed against a mold to be elastically deformed, cut in a slice shape in that state, and a shape corresponding to the mold is obtained by removing an external force, and further punching into a desired shape. A method of manufacturing a molded article characterized by the following. 6. A cushion material corresponding to the mold by pressing the block-shaped cushion material against a mold having a sheet shape to elastically deform the cushion material, and then cutting the cushion material into slices and removing external force. And producing the cushion by punching out the cushion material. 7. A block-shaped cushion material is elastically deformed by being pressed against a sheet-shaped mold, and a cushion obtained by cutting the cushion material into slices in that state is placed on a sheet base material. A sheet comprising a cover material covered with the cushion, and edges of the cover material fixed to the sheet base material.