JP2002315655A - Cushion material and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a cushion material capable of achieving low resiliency when a person is seated and the feeling of stability after seating, and a method of manufacturing it. SOLUTION: This cushion 1 has a front layer 111, a back layer 112 located at the back of the front layer 111, and an intermediate layer 114 located between the front layer 111 and the back layer 112. The front layer 111 is made from low-hardness foam having a hardness of 196.1 N/314 cm<2> or less. The intermediate layer 114 is made from high-hardness foam having a hardness of more than 196.1 N/314 cm<2> . The back layer 112 is made from high-resiliency foam which is high in the property of absorbing vibration, with a resonance magnification of 3 times or less to the rate of vibration transmission, and with an impact resilience of 70% or more.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a cushion material used for a seat of a vehicle, an aircraft, a ship, a sofa used indoors, and the like.

[0002]

2. Description of the Related Art Conventionally, a cushion material used for a seat portion or a backrest portion of a seat of a vehicle or the like has two layers of a soft layer and a hard layer in order to improve the sitting comfort of a user of the seat. Those having a structure are used.

[0003]

However, in the cushioning material, the characteristics realized by combining the above-mentioned layers greatly affect the performance of the seat, such as seating comfort and riding comfort. In recent years, the performance required for the seat has become complicated and diversified, and a cushion material capable of flexibly responding to the performance and a method of manufacturing the cushion material are expected.

The present invention has been made in view of the above-mentioned conventional problems, and an object of the present invention is to provide a cushioning material capable of realizing a low repulsion force when seated and a sense of stability after seating, and a method of manufacturing the same. Things.

[0005]

A first invention has a surface layer in contact with the body of a seated person, and a back layer positioned on the back side of the surface layer and supported by a support member made of a hard material. An intermediate layer is provided at least in part between the base layer and the back layer. The surface layer, the back layer, and the intermediate layer are each made of a foam, and the foam constituting the surface layer constitutes the intermediate layer. The foam constituting the back layer has a vibration characteristic different from that of the foam constituting the surface layer and the intermediate layer, and the respective layers are chemically formed at a boundary where they are in contact with each other. A cushioning material characterized by being integrated by bonding (claim 1).

Next, the function and effect of the present invention will be described.
In the cushioning material according to the present invention, the foam constituting the surface layer is made of a foam softer than the foam constituting the intermediate layer. Thereby, a low repulsion force can be realized when sitting. Also, the foam constituting the intermediate layer is
It is made of a foam harder than the foam constituting the surface layer. Thereby, the rigidity of the cushion material as a whole can be improved. Therefore, it is possible to prevent the user from sinking extremely deep after sitting down, and to realize a sense of stability that can stably maintain the posture of the user.

The foam constituting the back layer has vibration characteristics different from those of the foam constituting the surface layer and the intermediate layer. Therefore, vibrations transmitted from the floor of the vehicle or the like can be effectively absorbed while the vehicle or the like provided with the cushion material is traveling. Further, the respective layers of the surface layer, the intermediate layer and the back layer are integrated by being chemically bonded at a boundary where they are in contact with each other. Therefore, the bonding between the respective layers is strong, and the layers can be prevented from separating during use.

According to a second aspect of the present invention, there is provided a method of manufacturing a cushion material in which foam molding is performed using a lower mold and an upper mold. A first cavity for molding a first central portion having a back layer positioned thereon, and an intermediate layer positioned between the surface layer and the back layer; A second cavity for forming a second central portion made of the same material as the back layer is formed, and a front and rear partition plate is provided between the first cavity and the second cavity. On the other hand, the upper mold has a bottom forming surface for forming a bottom of the cushion material. In performing the foam molding, the first cavity has a foaming property and a foaming property. When the body becomes the first
Injecting a first raw material exhibiting the above physical properties, and from above the first raw material, a third raw material having a foaming property and exhibiting a third physical property different from the first physical property when the foam is formed. While the second cavity has a foaming property,
Injecting a second raw material exhibiting a second physical property different from the first physical property and the third physical property when it becomes a foam,
Thereafter, the lower mold and the upper mold are closed, a flow port is formed between the bottom forming surface of the upper mold and the upper ends of the front and rear partition plates, and the respective raw materials are foamed. 3
The raw material flows forward so as to cover the first raw material at the time of foaming and to follow the flow at the flow front end of the first raw material, and the second raw material flows at the time of the foaming. The fluid flows from the two cavities through the fluid port into the first cavity, and flows forward so as to cover the third material and follow the flow of the tip of the third material. There is provided a method of manufacturing a cushion material, characterized in that the cushion material is constituted.

Here, in the present invention, the front-back direction means
The direction is such that the first central portion side or the first cavity side of the cushion material is the front, and the second central portion side or the second cavity side of the cushion material is the rear. The left-right direction is a direction perpendicular to the front-rear direction with both sides of the cushion material or the side cavities being left and right. The vertical direction is the vertical direction of the vehicle body when the cushion material is attached to the vehicle body, and is the direction of gravity when manufacturing the cushion material (the same applies hereinafter).

Next, the operation and effect of the present invention will be described.
In the present invention, the first raw material is injected in the first cavity, and foams and flows in the first cavity. Further, the third raw material is injected from above the first raw material that foams and flows in the first cavity, and foams and flows above the first raw material. The third raw material foams and flows forward, covers the first raw material, and flows forward so as to follow the flow of the flow front portion of the first raw material. Therefore, the first raw material can be prevented from foaming and flowing upward without limitation due to the weight of the third raw material. On the other hand, the second raw material is injected in the second cavity, foams and flows in the second cavity, and also foams and flows in the first cavity over the front and rear partition plates.

The first raw material, the second raw material and the third raw material
After the injection of each raw material is completed, the lower mold and the upper mold are closed. At this time, a flow port is formed between the bottom forming surface of the upper die and the upper ends of the front and rear partition plates. Thereby, the flow rate of the flow of the second raw material foaming and flowing from the second cavity to the first cavity can be restricted. The second raw material foams and flows forward, covers the third raw material, and flows forward so as to follow the flow of the flow front portion of the third raw material. Therefore, the third raw material can be prevented from foaming and flowing upward indefinitely due to the weight of the second raw material, and the third raw material can be caused to flow almost only forward.

Further, the third raw material promotes the flow of the first raw material in front of the flow front end portion, and when the flow front end portion of the first raw material reaches the front front end of the first cavity, the flow proceeds further. The forward flow is blocked, while the backward flow is blocked by the flow of the third raw material that has been pursued, so that it flows upwards over the leading edge. Therefore, the first raw material can wrap around the third raw material and form a front edge at the front end of the first cavity.

[0013] Thus, finally, the first raw material becomes a foam having the first physical properties, and the first raw material becomes the first foam.
A surface layer is formed below the cavity, and a front edge is formed at the front end of the first cavity. On the other hand, the third raw material becomes a foam having the third physical property, and forms the intermediate layer between the lower part and the upper part of the first cavity. The second raw material becomes a foam having the second physical property, forms the back layer above the first cavity, and forms the second central portion in the second cavity. In the present invention, the first, second, and third physical properties refer to hardness, vibration absorption, rebound resilience, and the like exhibited by a foam formed from each of the first, second, and third raw materials. This concept includes various physical properties (characteristics).

Further, in the present invention, the flow rate of the foaming flow of the second raw material can be adjusted to limit the speed of the foaming flow of the second raw material, the first raw material, and the third raw material. Therefore, it is possible to reduce local thickness variations in the surface layer of the first raw material, the back layer of the second raw material, and the intermediate layer of the third raw material.

[0015] Further, by using a raw material having a hardness after foaming (a hardness at the time of forming a foam) of the first raw material that is lower than the hardness of the third raw material after foaming, the surface layer can be intermediately formed. It can be composed of a foam having a lower hardness than the layer. On the other hand, by using a raw material whose foamed hardness is higher than the foamed hardness of the first raw material for the third raw material, the intermediate layer is formed of a foam having a higher hardness than the surface layer. Can be. Therefore, according to the present invention, it is possible to easily manufacture a cushion material that can realize a low repulsion force when sitting and a sense of stability after sitting.

According to a third aspect of the present invention, there is provided a method of manufacturing a cushion material in which foaming is performed using a lower mold and an upper mold, wherein the lower mold has a surface layer positioned on the front side of the cushion material and a rear layer positioned on the back side. A first cavity for molding a first central portion having a back layer positioned thereon, and an intermediate layer positioned between the surface layer and the back layer; and a first cavity disposed behind the first cavity and the back cavity. A second cavity for molding a second central portion made of the same material as the layer, and a material formed of the same material as the intermediate layer on the surface side of the cushion material between the first cavity and the second cavity; A third cavity for molding a third central portion having an intermediate surface layer to be formed and the back layer is formed, and an intermediate partition plate is provided between the first cavity and the third cavity. Together with A front / rear partition plate is provided between the third cavity and the second cavity, while the upper mold has a bottom forming surface for forming a bottom of the cushion material, In performing the molding, a first raw material having a foaming property and exhibiting a first physical property when it is formed into a foam is injected into the first cavity, while, into the second cavity, A second raw material having a foaming property and exhibiting a second physical property different from the first physical property when the foam is formed is injected, and the third cavity has a foaming property and has a foaming property. Injecting a third raw material exhibiting third physical properties different from the first physical properties and the second physical properties when it becomes a body, and then closing the lower mold and the upper mold, An intermediate flow port is provided between the bottom forming surface of the upper die and the upper end of the intermediate partition plate. Front and rear flow ports are respectively formed between the bottom forming surface and the upper ends of the front and rear partition plates to foam the respective raw materials, and the third raw material is supplied from the third cavity to the intermediate flow ports at the time of the foaming. Flow into the first cavity through the first raw material, and flow forward to cover the first raw material so as to follow the flow of the flow front end of the first raw material. Flows from the second cavity through the flow port into the third cavity and the first cavity, and covers the third raw material to follow the flow of the flow front end of the third raw material. The method for manufacturing a cushion material is characterized in that the cushion material is configured to flow forward as described above.

Next, the operation and effect of the present invention will be described.
In the present invention, the first raw material is injected in the first cavity, and foams and flows in the first cavity. Further, the third raw material is injected in the third cavity, foams and flows in the third cavity, and also foams and flows in the first cavity over the intermediate partition plate. Further, the second raw material is injected in the second cavity, foams and flows in the second cavity, and also foams and flows in the third cavity over the front and rear partition plates.

The first raw material, the second raw material and the third raw material
After the injection of each raw material is completed, the lower mold and the upper mold are closed. At this time, an intermediate flow port is formed between the bottom forming surface of the upper die and the upper end of the intermediate partition plate.
A front and rear flow port is formed between the bottom forming surface and the upper end of the front and rear partition plate.

By the front and rear flow ports, the flow rate of the flow of the second raw material foaming and flowing into the third cavity beyond the second cavity can be limited. The second raw material foams and flows forward, covers the third raw material, and flows forward so as to follow the flow of the flow front portion of the third raw material. Therefore, the third raw material can be prevented from foaming and flowing upward indefinitely due to the weight of the second raw material, and the third raw material can be caused to flow almost only forward.

The third raw material is supplied to the first fluid by the intermediate fluid port.
The flow rate of the foam flowing from the third cavity to the first cavity and the flow rate of the foam flowing from the third cavity to the first cavity through the upper portion of the third raw material are determined by following the flow of the raw material at the leading end. Can be restricted. This third
The raw material foams and flows forward, covers the first raw material, and flows forward so as to follow the flow of the flow front end of the first raw material. Therefore, the first raw material can be prevented from foaming and flowing upward without limitation by the weight of the third raw material, and the first raw material can be flowed almost only forward.

Further, the third raw material promotes the flow of the first raw material to the front of the flow front end portion. When the flow front end of the first raw material reaches the front front end portion of the first cavity, the flow proceeds further. The forward flow is blocked, while the backward flow is blocked by the flow of the third raw material that has been pursued, so that it flows upwards over the leading edge. Therefore, the first raw material can wrap around the third raw material and form a front edge at the front end of the first cavity.

As described above, finally, the first raw material becomes a foam having the first physical properties, and
A surface layer is formed below the cavity, and a front edge is formed at the front end of the first cavity. On the other hand, the second raw material becomes a foam having the second physical property, forms the back layer above the first cavity and the third cavity, and forms the second layer in the second cavity.
Form a central part. In addition, the third raw material becomes a foam having the third physical property, forms the intermediate layer between the lower part and the upper part of the first cavity, and forms the intermediate surface layer below the third cavity. Form. In the present invention, the first, second and third physical properties are defined as the first and second physical properties.
This is a concept that includes various physical properties (characteristics) such as hardness, vibration absorption, and rebound resilience of a foam formed from each of the raw material, the second raw material, and the third raw material.

In the present invention, the flow rate of the foaming flow of the second raw material and the third raw material is adjusted to adjust the flow rate of the first raw material,
The speed of the foaming flow of the second raw material and the third raw material can be limited. Therefore, it is possible to reduce local thickness variations in the surface layer of the first raw material, the back layer of the second raw material, and the intermediate layer of the third raw material.

Also, by using a raw material having a hardness after foaming (hardness when it becomes a foam) as the first raw material, which is lower than the hardness after foaming of the third raw material, the surface layer can be intermediately formed. It can be composed of a foam having a lower hardness than the layer. On the other hand, by using a raw material whose foamed hardness is higher than the foamed hardness of the first raw material for the third raw material, the intermediate layer is formed of a foam having a higher hardness than the surface layer. Can be. Therefore, also according to the present invention, it is possible to easily manufacture a cushion material capable of realizing a low repulsion force when sitting and a sense of stability after sitting.

[0025]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The preferred embodiments of the present invention will be described. The cushioning material according to the first invention (claim 1) can be used, for example, as a seat (seat cushion) or a backrest (seat back) in an automobile seat. The hardness (one of the physical properties) of the foam constituting the surface layer is 196.1N.
/ 314 cm ² or less (claim 2). In this case, the cushioning material can easily realize a low repulsion force at the time of sitting. The lower limit of the hardness of the foam constituting the surface layer is 58.8 N /
More preferably, it is 314 cm ² (6 kgf / 314 cm ² ) or more. The hardness of the foam constituting the surface layer is 127.5 N / 314 cm ² (13 kgf / 3
It is more preferred that it is 14 cm ² ) or less.

The hardness (one of the physical properties) of the foam constituting the intermediate layer preferably exceeds 196.1 N / 314 cm ² (claim 3). In this case, the cushion member can easily realize a sense of stability after sitting. The upper limit of the hardness of the foam constituting the intermediate layer is 686.5 N / 314 cm ² (70 kgf
/ 314 cm ² ) or less. In addition, the relationship between the hardness of the foam constituting the surface layer and the hardness of the foam constituting the intermediate layer may be relatively different as long as the minimum function as the cushioning material is not impaired. I just need.

It is preferable that the back layer is made of a foam having higher vibration absorption (one of physical properties) than the surface layer and the intermediate layer. In this case, when the cushion material is installed in a vehicle or the like, the cushion material absorbs vibration transmitted from the floor surface of the vehicle or the like, and can suppress the transmission of the vibration to the intermediate layer and the surface layer. Specifically, the foam constituting the back layer can be a foam having a resonance magnification of 3 times or less (claim 5). In addition, the smaller the resonance magnification is, the easier it is to absorb vibration.

Preferably, the back layer is made of a foam having higher rebound resilience (one of physical properties) than the surface layer and the intermediate layer. In this case, when the seat portion or the backrest portion of the seat is constituted by the cushion material,
A backing layer can act as a substitute for a spring in the seat or back. Specifically, the foam constituting the back layer can be made of a foam having a rebound resilience of 70% or more. The larger the resilience, the better.

It is preferable that the surface layer, the intermediate layer, and the back layer are all made of a polyurethane resin foam. In this case, the raw materials for the polyurethane resin are easily available, and the respective layers can be formed easily and economically. The cushioning material has a central portion on which a person sits, and both side portions formed to protrude on both left and right sides of the central portion. The central portion includes the surface layer and the intermediate layer in order from the surface side. , The back layer is laminated, and both side portions are preferably formed integrally with the back layer.
In this case, the cushion material can be used as a seat (seat cushion) in a seat of a vehicle such as an automobile.

Further, the cushioning material has a central portion for receiving the back of a person and both side portions formed to protrude on both left and right sides of the central portion. , The intermediate layer and the back layer are laminated, and the both side portions are preferably formed integrally extending from the back layer. In this case, the cushion material can be used as a backrest (seat back) in a seat of a vehicle such as an automobile.

The cushion material formed by the manufacturing method according to the second invention (claim 11) can be used, for example, for a seat portion or a backrest portion of an automobile seat. The lower mold is provided with side cavities for molding side portions disposed on both left and right sides of the cushion material, and a first cavity is provided between the side cavities and the first cavities. A side partition plate is provided between the side cavity and the second cavity, and a second side partition plate is provided between the side cavity and the second cavity. The flow port is provided between the bottom forming surface of the upper die and the side partition. It is preferable to form it also between the upper end of the plate.
2).

In this case, finally, the second raw material is
The back layer is formed above the first cavity, the second central portion is formed in the second cavity, and the side portion is formed in the side cavity. In this case, the second raw material is injected into the second cavity,
The foam can flow over the second side partition plate toward the side cavity. Therefore, the side portion can be formed without directly injecting the second raw material into the side cavity.

Further, in the cushion material, the second
The central portion is preferably cut off after the foam molding when there is a possibility that the seated person may feel uncomfortable (claim 13). In this case, when the second central portion is made of the high-hardness foam, the high-hardness foam is not located on the surface side of the cushion material, so that it is possible to exhibit a better sitting comfort. However, if the second central portion can be provided at a position where the body of a seated person does not come into contact, the resection is unnecessary.

The cushion material formed by the manufacturing method according to the third invention (claim 14) can also be used for, for example, a seat portion or a backrest portion of an automobile seat. The lower mold has side cavities for molding side portions disposed on both left and right sides of the cushion material, and a first side cavity is formed between the side cavities and the first cavities. A second side partition plate provided between the side cavity and the second cavity, and a third side partition plate provided between the side cavity and the third cavity. The opening is preferably formed between the bottom forming surface of the upper die and the upper end of each of the side partition plates.

In this case, finally, the second raw material is
The back layer is formed above the first cavity, the second central portion is formed in the second cavity, and the side portion is formed in the side cavity. In this case, the second raw material is injected into the second cavity,
The foam can flow over the second side partition plate toward the side cavity. Therefore, the side portion can be formed without directly injecting the second raw material into the side cavity.

Further, in the cushion material, the second
It is preferable that the central portion and the third central portion are cut off after the foam molding when there is a possibility that the seated person may be uncomfortable. In this case, when the second central portion and the third central portion are made of the high-hardness foam,
Since the high-hardness foam is not located on the surface side of the cushioning material, it is possible to provide a better sitting comfort. However, if the second central portion and the third central portion can be provided at positions where the body of a seated person does not come into contact, the resection is unnecessary.

An embodiment of the present invention will be described below with reference to the drawings. Example 1 As shown in FIG.
Consists of a laminate of polyurethane resin foam,
11 and a back layer 112 located on the back side of the surface layer 111.
And an intermediate layer 114 located between the surface layer 111 and the back layer 112. Further, the above-mentioned layers are integrated by being chemically bonded at a boundary where they are in contact with each other. The surface layer 111, the back layer 112, and the intermediate layer 114 are each made of a foam.

The foam constituting the surface layer 111 is made of a foam softer than the foam constituting the intermediate layer 114. Specifically, the surface layer 111 has a hardness of 196.1 N /
314 cm ² (20 kgf / 314 cm ² ) or less of a low-hardness foam, and the intermediate layer 114 has a hardness of 19
6.1N / 314cm ² (20kgf / 314cm ² )
It is composed of a foam of high hardness exceeding

The back layer 112 may be made of a foam having high vibration absorbing properties or a foam having high resilience. Specifically, in the former case, a foam having a resonance magnification of not more than 3 times the vibration transmissibility is used, and in the latter case, the rebound resilience is 70%.
The above foam is used. The high vibration absorption means that the ability to absorb vibration is high, and the high rebound resilience means that the rebound resilience is high.

Here, the value of the hardness is determined according to the JIS standard.
It complies with ISK6401. Specifically, this hardness is expressed as a compressive load when a disk having a diameter of 20 cm is pressed against the cushion material 1 and the cushion material 1 is bent by 25% with respect to its thickness. In the art, this hardness is sometimes referred to as “25% hardness”. The value of the resonance magnification with respect to the above-mentioned vibration transmissibility is J
JASOB408-8 of ASO standard (Japanese automobile standard)
7, and the value of the rebound resilience is in accordance with JASOB408-89 of the JASO standard.

The details will be described below. The cushion material 1 is used for a seat of a seat in an automobile. As shown in FIGS. 1, 2 (a) and 2 (b), the cushion material 1 is made of a polyurethane resin foam as described above, and has a front portion 11 located at the front,
The front part 11, the rear part 13, and the side parts 12 located on the left and right sides of the front part 11, the rear part 13, and the center part 14 are provided. .

The front part 11 includes the surface layer 111,
The rear portion 13 and the side portion 12 are made of the same material as that of the back layer 112. In the following description, it is assumed that the back layer 112 is made of a highly vibration-absorbing foam.

The center portion 14 is located on the front surface side of the cushion material 1 and is made of the same material as that of the intermediate layer 114.
On the back side of the intermediate surface layer 115, a back layer 112 extends from the front portion 11. Side grooves 17 are formed between the front part 11 and the center part 14 of the cushioning material 1 and the left and right side parts 12 to separate the surface layer 111 and the side parts 12. The front portion 11 and the center portion 14 of the cushioning material 1 are also provided.
An intermediate groove 16 is formed between them to separate the surface layer 111 from the intermediate surface layer 115. The center 1
A front-rear groove 15 is formed between the rear part 4 and the rear part 13 to separate the intermediate surface layer 115 from the rear part 13.

At the front end of the front part 11, a surface layer 11 is provided.
A front edge portion 113 made of a foam molded from the same first raw material 41 as that of the first raw material 41 is formed. This front edge 113
Are formed so as to wrap around and surround the surface side of the intermediate layer 114.

The surface layer 111 and the front edge 113 of the front portion 11 are made of the low-hardness polyurethane resin foam. The intermediate layer 114 of the front portion 11 and the intermediate surface layer 115 of the center portion 14 are made of a polyurethane resin foam having a higher hardness than the foam of the surface layer 111 and the front edge 113. The side part 12 and the rear part 13 are made of polyurethane resin foam having high vibration absorption.

The periphery of the surface layer 111 is separated from the peripheral foamed side portions 12 and the center portion 14 by the side grooves 17 and the intermediate grooves 16, so that when the surface layer 111 is compressed and deformed. In addition, the advantage of the sufficiently soft foam can be exhibited without being pulled by the side portion 12 and the center portion 14. An intermediate layer 114 made of a rigid foam is provided on the back side surface of the surface layer 111.
Therefore, when the user sits down, extremely deep sinking can be prevented, and the sitting comfort of the user can be made comfortable. After molding, the surface of the cushion material 1 is covered with a cover such as a cloth, and becomes a seat portion of the seat.

Next, the molding die 6 as the lower die 2 and the upper die 3 will be described. Here, in this example, the front portion 11 is provided in the first central portion, the rear portion 13 is provided in the second central portion, the center portion 14 is provided in the third central portion, and the center portion 14 is provided in the first cavity. The front cavity 21, the rear cavity 23 corresponds to the second cavity, and the center cavity 24 corresponds to the third cavity. In addition, the first side partition plate is attached to the front side partition plate 27,
The second side partition plate corresponds to the rear side partition plate 28, and the third side partition plate corresponds to the center side partition plate 29.

As shown in FIGS. 4 and 5 (a) to 5 (c),
The lower die 2 has a front cavity 21 for molding the front part 11, a rear cavity 23 for molding the rear part 13, and a center cavity 24 for molding the center part 14. ing. An intermediate partition plate 26 is provided between the front cavity 21 and the center cavity 24, and a front and rear partition plate 25 is provided between the center cavity 24 and the rear cavity 23.

The lower mold 2 has the side portions 12
A front side partition plate 27 is formed between the side cavity 22 and the front cavity 21 and a rear side portion is formed between the side cavity 22 and the rear cavity 23. A partition plate 28 is provided, and a center side partition plate 29 is provided between the side cavity 22 and the center cavity 24. On the other hand, the upper die 3 has a bottom forming surface 31 for forming the bottom of the cushion material 1.

The rear side partition plate 28 has its upper end 2
The height of 81 is lower than the height of the upper end 251 of the front and rear partition plate 25 in the direction of gravity. Therefore, before the second raw material 42, which will be described later, crosses the upper end 251 of the front and rear partition plate 25 and starts foaming and flows into the center cavity 24, the second raw material 42 crosses the upper end 281 of the rear side partition plate 28 and enters the side cavity 22. The foaming flow can be started at once. Thereby, the second raw material 4
2 only needs to be injected into the rear cavity 23, and the time and effort for directly injecting it into the side cavity 22 can be omitted.

The center side partition plate 29 has its upper end 291 connected to the front and rear partition plate 25 and the intermediate partition plate 26.
It is higher than the height. Therefore, it is possible to prevent a third raw material 43 described later from foaming and flowing from the center cavity 24 toward the side cavities 22.

Next, the entire device for manufacturing the cushion material 1 will be described. As shown in FIG.
Is formed so that the surface side of the cushion material 1 faces downward and has the shape of the surface side. On the other hand, the upper die 3 is rotatably connected to the lower die 2 by a hinge portion 32 and can be opened and closed. The cushion material 1 is formed by the manufacturing device 5. Manufacturing equipment 5
Are the lower mold 2 and the upper mold 3, the mold 6, the injection head 51, the raw material tank 52, and the metering pumps 551,
52. The molding die 6 is mounted on a trolley 53, and the trolley 53 is mounted on a conveyor 54.

The first raw material 41, the second raw material 42 and the third raw material 42
The liquid polyol-based raw material constituting the raw material 43 is held in a holding chamber 521 of the raw material tank 52, and is sent to the injection head 51 by a metering pump 551. The polyol-based raw material is supplied to the injection head 51 and the holding chamber 521 by the metering pump 551.
It can be circulated between. Further, the polyol-based raw material is carried from the holding chamber 521 to the injection head 51 through the supply pipe 561, and when not injected into the lower mold 2 from the injection head 51, passes through the collection pipe 571 from the injection head 51 to the holding chamber 521. Is to be collected.

On the other hand, the liquid isocyanate-based raw material constituting the first raw material 41, the second raw material 42, and the third raw material 43 is held in the holding chamber 522 of the raw material tank 52, and is supplied by the metering pump 552. It is sent to the injection head 51. Similarly, the isocyanate-based raw material can be circulated between the injection head 51 and the holding chamber 522 by the metering pump 552. The isocyanate-based raw material is carried from the holding chamber 522 to the injection head 51 through the supply pipe 562, and when not injected into the lower mold 2 from the injection head 51, passes from the injection head 51 through the collection pipe 572 to the holding chamber 522. Is to be collected.

Inside the injection head 51, the polyol-based material and the isocyanate-based material sent from the material tank 52 can be mixed. The injection head 51 is provided with an injection nozzle 511,
The injection nozzle 511 can be opened and closed by a control valve such as a hydraulic cylinder (not shown). Then, the first raw material 41, the second raw material 42, and the third raw material 43 can be injected by opening the injection nozzle 511 for a desired time. Also, the injection head 51
Front cavity 21 and rear cavity 2 of lower mold 2
3 is movable so that injection can be performed.

The metering pumps 551 and 552 are
It is a metering pump, and the supply amount to the injection head 51 can be increased or decreased by changing the circulation amount of the polyol-based raw material or the isocyanate-based raw material by increasing or decreasing the rotation speed. That is, by changing the rotation speed of each of the metering pumps 551 and 552, the weight mixing ratio between the polyol-based material and the isocyanate-based material can be changed.
Then, the first raw material 41, the second raw material 42, and the third raw material 42 are mixed by mixing the raw materials to the determined weight mixing ratio.
The raw material 43 can be produced.

The injection head 51, the raw material tank 52 and the metering pumps 551, 5 in the manufacturing apparatus 5 are used.
If the adjustment of the mixing ratio is not possible due to the physical properties such as hardness, vibration absorption and rebound resilience required for each of the above layers, prepare a plurality of devices such as 52 according to the difference in the raw materials used. There is also.

The molding die 6 is placed on the carriage 53, and when it is transported by the conveyor 54, it is transported while riding on the carriage 53. A plurality of molding dies 6 placed on a carriage 53 can be placed on the conveyor 54, and the first raw material 41, the second raw material 42, and the third raw material 43 into which the injection head 51 injected the above-described first raw material 41. The molding dies 6 can be sequentially sent out. Thus, by arranging a plurality of the forming dies 6 on the conveyor 54, a plurality of the cushion materials 1 can be efficiently formed. The upper die 3 is provided with a first raw material 41, a second raw material 42 and a third raw material 42 from the injection head 51.
It is open when the raw material 43 is supplied to the lower mold 2.

Next, a method of manufacturing the cushion material 1 using the above-described molding die 6 will be described. First, FIGS. 4 and 5
As shown in (a) to (c), the liquid second raw material 42 is
The injection is performed from the injection nozzle 511 of the injection head 51 into the rear cavity 23 of the lower die 2. And the second raw material 42
Extends into the rear cavity 23.

As shown in FIGS. 6 and 7A to 7C, the liquid third raw material 43 is injected into the center cavity 24 of the lower die 2 from the injection nozzle 511.
Then, the third raw material 43 spreads in the center cavity 24.

As shown in FIGS. 8 and 9 (a) to 9 (c), the liquid first raw material 41 is placed at a position behind the middle position in the front-rear direction of the front cavity 21 of the lower die 2. , From the injection nozzle 511. Then, the first raw material 41 flows to the left and right sides and to the rear, and flows forward in the front cavity 21 with the flow front end 411 at the head.

The second raw material 42 is supplied to the rear cavity 23
After the interior is filled, foaming and volume expansion are started by a chemical reaction, and the foam flows over the upper end 281 of the rear side partition plate 28 and flows into the side cavity 22. Also,
Similarly, the second raw material 42 is directed forward with the flow front end portion 421 at the top, while covering the third raw material 43 filled with the center cavity 24 over the upper end 251 of the front and rear partition plate 25 in the same manner. It foams and flows.

As shown in FIGS. 10 and 11A to 11C, the first raw material 41, the second raw material 42 and the third
After the injection of each raw material 43 is completed, the lower die 2 and the upper die 3 are closed. At this time, the bottom forming surface 31 of the upper die
An intermediate flow port 262 having a fixed opening area is formed between the upper surface 261 and the upper end 261 of the intermediate partition plate 26.
In addition, the bottom forming surface 31 and the upper end 2 of the front and rear partition plate 25
A front-rear flow port 252 having a fixed opening area is formed between the front and rear flow ports 51. The opening area of each of the front and rear flow ports 252 and the intermediate flow port 262 is determined by the height of each of the front and rear partition plates 25 and the intermediate partition plate 26, respectively.
It can be adjusted by adjusting the shape and the like.

As shown in FIGS. 12 and 13 (a) to (c), the second raw material 42 foams and flows from the rear cavity 23 through the front and rear flow ports 252 to the center cavity 24 at the time of foaming. , And an intermediate fluid port 262
Through the front cavity 21. At this time, the second raw material 42 foams and flows forward, and the third raw material 4
3 and prevents the third raw material 43 from foaming and flowing upward without limitation due to the weight of the second raw material 42.

The flow front 421 of the second raw material 42
Flows forward so as to follow the flow of the flow front portion 431 of the third raw material 43. As described above, the front and rear flow ports 252 allow the second raw material 42 to pass through the rear cavity 2.
The flow rate and direction of the flow foaming into the center cavity 24 beyond 3 can be limited.

The third raw material 43 foams and flows from the center cavity 24 through the intermediate flow port 262 to the front cavity 21 at the time of foaming. At this time, the third raw material 43 foams and flows forward and the first raw material 41
And the first raw material 43 weighs the first raw material 43 by its own weight.
The raw material 41 is prevented from foaming and flowing upward indefinitely. In addition, the flow front 431 of the third raw material 43 is
The raw material 41 flows forward so as to follow the flow of the flow front end portion 411.

The third raw material 4 is supplied through the intermediate fluid port 262.
The flow rate and direction of the flow of the third and second raw materials 42 foaming and flowing into the front cavity 21 beyond the center cavity 24 can be restricted. The third raw material 43 is
The foaming flow to the side cavity 22 is blocked by the center side partition plate 29, and the foaming flow to the rear is
It is blocked by the second raw material 42 which foams and flows from behind.

Also, the first raw material 4
1 is promoted, and the flow front end 411 of the first raw material 41 becomes the front front end 21 of the front cavity 21.
When it reaches 1, further forward flow is blocked, while backward flow follows the third raw material 43
Of the front end 211
It flows upward. Therefore, the first raw material 41
Around the outside of the third raw material 43, a front edge portion 113 can be formed at a front end portion 211 of the front cavity 21.

After the second raw material 42 is filled in the side cavity 22, the third raw material 42 is supplied through a fluid port formed between the bottom forming surface 31 and the upper end of each of the side partition plates. The upper part of 43 joins with the part which has foamed and flowed.

As described above, FIGS.
Finally, as shown in FIG.
Forms a surface layer 111 below the front cavity 21 and forms a front edge 113 at a front end 211 of the front cavity 21. In addition, the second
The raw material 42 forms the back layer 112 above the front cavity 21 and the center cavity 24 and forms the rear portion 13 in the rear cavity 23. Further, the third raw material 43 forms the intermediate layer 114 between the lower part and the upper part of the front cavity 21, and forms the intermediate surface layer 115 below the center cavity 24.

In the present embodiment, the flow rate of the foaming flow of the second raw material 42 and the third raw material 43 is adjusted to
The speed of the foaming flow of the raw material 41, the second raw material 42, and the third raw material 43 can be limited. Therefore, the first raw material 41
Of the surface layer 111, the back layer 112 of the second raw material 42, and the intermediate layer 114 of the third raw material 43.

Then, after the first raw material 41 is foamed,
Has a hardness of 196.1N / 314cm ²(20kgf / 3
14cm²) By using the following raw materials,
The layer 111 can be made of a low-hardness foam. This
As a result, a low repulsion force can be realized when sitting.
You.

The third raw material 43 has a hardness after foaming of 196.1 N / 314 cm ² (20 kgf /
By using a raw material exceeding 314 cm ² ), the intermediate layer 114 can be made of a foam having high hardness.
Thereby, the rigidity of the cushion material 1 as a whole can be improved. Therefore, it is possible to prevent the user from sinking extremely deep after sitting down, and to realize a sense of stability that can stably maintain the posture of the user. Therefore, it is possible to easily manufacture the cushion material 1 that can realize a low repulsion force when sitting and a sense of stability after sitting.

The first raw material 41, the second raw material 42, and the third raw material 43 are all a mixture of a polyol-based material and an isocyanate-based material. That is, since these raw materials are originally the same type of raw materials for the polyurethane resin foam, the surface layer 111, the back layer 112, the front edge 113, the intermediate layer 114, and the intermediate surface layer 11 are used.
5. The boundary layers of the side part 12 and the rear part 13 are integrated by chemical bonding in the boundary layer when foaming.

The center portion 14 and the rear portion 13 of the foamed cushion material 1 may be cut off after the foaming, if there is a possibility that the seated person may feel uncomfortable. In this case, since the high-hardness foam constituting the center portion 14 is not located on the front surface side of the cushion material, it is possible to exhibit a better sitting comfort.

In this example, the center cavity 24 was provided in the lower mold 2 by the intermediate partition plate 26, and the third raw material 43 was injected into the center cavity 24 to perform foam molding. In contrast, FIG.
As shown in (1), the third raw material 43 may be injected into the front cavity 21 and foam molding may be performed without providing the center cavity 24 and the intermediate partition plate 26. In this case, it is preferable to use a raw material having a high reaction rate as the first raw material 41. Further, the third raw material 43 is injected onto the first raw material 41 after the reaction of the first raw material 41 progresses to some extent and the first raw material 41 is cured to such an extent that the first raw material 41 is not crushed by the weight of the third raw material 43. Is preferred.

Example 2 In this example, the optimum cushioning material 1 was formed by changing the mixing ratio of the polyol-based material and the isocyanate-based material used for the first raw material 41, the second raw material 42, and the third raw material 43. This is an example. Other configurations are the same as those of the first embodiment.

The polyol-based raw material is mainly composed of polypropylene glycol (PPG), a polymer graft-polymerized polyol (POP) or a mixed raw material of PPG and POP, and water (1-2 wt% of the total raw material), A mixture of a graded amine catalyst, a crosslinking agent and a silicone foam stabilizer.
In the second raw material 42, it is preferable to use a highly active silicone having a high foaming action as the silicone foam stabilizer, thereby preventing the burst of bubbles at the time of molding the foam and providing a large number of fine particles. It becomes easy to form closed cells, and the vibration absorption can be increased. The isocyanate-based raw material is mainly composed of a mixed raw material of TDI (tolylene diisocyanate) and crude MDI (diphenylmethane di4,4 diisocyanate).

The first raw material 41 is a polyol-based raw material in which the ratio of PPG to POP is PPG: POP = 80: 20 to 100: 0, and the ratio of TDI to crude MDI is TDI: crude MDI = 80: 20 mixed raw materials. The mixing ratio between the polyol-based material (P) and the isocyanate-based material (I) is P: I = 100: (30
To 35). The surface layer 111 foamed and formed from the first raw material 41 has a hardness of 58.8-12.
7.5N / 314cm ² (6 to 13kgf / 314cm
^2), made of foam density is 45~80kg / ^{m 3.}

The third raw material 43 is composed of a polyol-based raw material in which the ratio of PPG to POP is PPG: POP = 40: 60 to 0: 100, and the ratio of TDI to crude MDI is TDI: crude MDI = 80: It is composed of a mixed raw material with an isocyanate-based raw material of 20 to 50:50. The mixing ratio between the polyol-based material (P) and the isocyanate-based material (I) is P: I = 100: (30 to 40). The intermediate layer 114 formed by foaming the third raw material 43 has a hardness of 245.2 to 686.5N.
/ 314cm ² (25-70kgf / 314cm ² ),
Density of the foam is 50~70kg / ^{m 3.}

The second raw material 42 is a polyol-based raw material in which the ratio of PPG to POP is PPG: POP = 90: 10 to 100: 0, and the ratio of TDI to crude MDI is TDI: crude MDI = 80: 20 to 60:40, which is a mixed raw material with an isocyanate-based raw material. The mixing ratio between the polyol-based material (P) and the isocyanate-based material (I) is P: I = 100: (30 to 35). The back layer 112 foamed and formed from the second raw material 42 has a hardness of 147.1 to 245.2 N /
314 cm ² (15-25 kgf / 314 cm ² ), density 45-80 kg / m ³ , rebound resilience 40-60
[%].

In the cushion material 1 having the composition of the raw material in this embodiment, the lower cavity 2 is provided with the center cavity 24 by the intermediate partition plate 26, and the third raw material 43 is injected into the center cavity 24. Foam molding was performed.

In the present embodiment, since the surface layer 111 is made of a soft foam, a low repulsion force can be realized when sitting. Further, since the intermediate layer 114 is made of a rigid foam, a sense of stability after sitting can be realized. Further, the back layer 112 is made of a foam having high vibration absorption. Therefore, the cushion material 1 absorbs vibration transmitted from the floor of the automobile, and the vibration is transmitted to the intermediate layer 11.
4 and the surface layer 111 can be suppressed.

When the cushioning material 1 is used as a seat of an automobile seat, a spring as an elastic material can be arranged below the seat. In this case, due to the synergistic effect of the cushion material 1 and the spring, it is possible to form a seat having a soft sitting comfort and a hold feeling such as guarding the body. Other example 1 of the above embodiment
The same operation and effect as described above can be obtained.

Example 3 In this example, too, the optimum cushioning material 1 was formed by changing the mixing ratio of the polyol-based material and the isocyanate-based material used for the first raw material 41, the second raw material 42, and the third raw material 43. This is an example. Other configurations are the same as those of the first embodiment.

The above-mentioned polyol-based raw material is mainly composed of polypropylene glycol (PPG), a polymer graft-polymerized polyol (POP) or a mixed raw material of PPG and POP, and water (3 to 4% by weight of the total raw material), A mixture of a graded amine catalyst, a crosslinking agent and a silicone foam stabilizer.
In the second raw material 42, it is preferable to use low-active silicone having a low foaming action as the silicone foam stabilizer, thereby making it easy to form continuous bubbles and increasing the rebound resilience. can do. The isocyanate-based raw material is mainly composed of a mixed raw material of TDI (tolylene diisocyanate) and crude MDI (diphenylmethane di4,4 diisocyanate).

The second raw material 42 is a polyol-based raw material in which the ratio of PPG to POP is PPG: POP = 60: 40 to 40:60, and the ratio of TDI to crude MDI is TDI: crude MDI = 80: 20 mixed raw materials. The mixing ratio between the polyol-based material (P) and the isocyanate-based material (I) is P: I = 100: (30
To 35).

The back layer 112 foamed and formed from the second raw material 42 has a hardness of 196.1 to 29.
4.2N / 314cm ² (20-30kgf / 314c
m ² ), density 50-70 kg / m ³ , rebound resilience 7
It is made of a foam that is 0 to 80%.

The first raw material 41 and the third raw material 43
And the properties of the surface layer 111 and the intermediate layer 114 are the same as in the second embodiment. Further, in the cushion material 1 having the composition of the raw material in this example, the lower cavity 2 is provided with the center cavity 24 by the intermediate partition plate 26, and the third raw material 43 is injected into the center cavity 24 to perform foam molding. went.

In this embodiment, the back layer 112 is made of a foam having high resilience. When the cushioning material 1 in this embodiment is used as a seat of a vehicle seat, the back layer 112 can act as a substitute for a spring. In this case, there is no need to provide the above spring specially.
The seat portion of the seat has a simple structure, and can provide a seating comfort with a cushion feeling utilizing high rebound resilience. In addition, the same functions and effects as those of the first embodiment can be obtained.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a cushion material according to a first embodiment.

FIG. 2A is a diagram showing the AA in FIG.
FIG. 2 is a sectional view taken along an arrow, and FIG.

FIG. 3 is an explanatory diagram illustrating a manufacturing apparatus according to the first embodiment.

FIG. 4 is a plan view showing a molding die in Example 1 in which a second raw material is injected.

FIGS. 5A and 5B are views showing a molding die in which a second raw material is injected in Example 1, and FIG. 5A is a cross-sectional view taken along the line AA in FIG. 4, and FIG. Fig. 4 (c)
FIG.

FIG. 6 is a plan view showing a molding die in a state where a third raw material is injected in the first embodiment.

FIGS. 7A and 7B are views showing a molding die in which a third raw material is injected in Example 1, and FIG. 7A is a cross-sectional view taken along the line AA in FIG. 6, and FIG. Figure, (c) Figure 6
FIG.

FIG. 8 is a plan view showing a molding die in Example 1 in which a first raw material is injected.

9A and 9B are diagrams showing a molding die in which a first raw material is injected in Example 1, and FIG. 9A is a cross-sectional view taken along the line AA in FIG. 8, and FIG. FIG. 8 (c)
FIG.

FIG. 10 is a plan view showing the molding die in a state where the upper die and the lower die are closed in the first embodiment.

11A and 11B are diagrams showing a molding die in a state where an upper die and a lower die are closed in Example 1, and FIG. 11A is a cross-sectional view taken along the line AA in FIG. 10, and FIG. Arrow cross section,
(C) A sectional view taken along the line CC in FIG.

FIG. 12 is a plan view showing a mold during foam molding in Example 1.

13A and 13B are diagrams showing a mold during foam molding in Example 1, and FIG. 13A is a cross-sectional view taken along the line AA in FIG.
FIG. 12B is a sectional view taken along the line BB in FIG. 12, and FIG.
FIG.

FIG. 14 is a plan view showing a molding die after foam molding in Example 1.

15 is a view showing a molding die after foam molding in Example 1, and FIG. 15 (a) is a sectional view taken along the line AA in FIG.
FIG. 14B is a sectional view taken along the line BB in FIG. 14, and FIG.
FIG.

FIG. 16 is a view corresponding to an arrow AA in FIG. 14 showing another lower mold according to the first embodiment, and is a cross-sectional view showing the lower mold when a third material is injected into the front cavity without providing the center cavity. .

[Explanation of symbols]

 1. . . 10. cushioning material, . . Front part, 111. . . Surface layer, 112. . . Back layer, 113. . . Leading edge, 114. . . Middle layer, 115. . . Intermediate surface layer, 12. . . 12. side part, . . Rear part, 14. . . Center part, 2. . . Lower mold, 21. . . Front cavity, 22. . . Side cavity, 23. . . Rear cavity, 24. . . Center cavity, 25. . . Front and rear partition plate, 252. . . Front and rear flow openings, 26. . . Intermediate partition plate, 262. . . 2. intermediate fluid port, . . Upper mold, 31. . . Bottom forming surface, 41. . . First raw material, 42. . . Second raw material, 43. . . Third raw material, 6. . . Mold,

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B68G 11/04 B68G 11/04 // B29K 75:00 B29K 75:00 105: 04 105: 04 B29L 31: 58 B29L 31:58 F term (reference) 3B096 AA01 AB07 AD07 4F204 AA42 AE07 AG03 AG20 AH26 EA01 EA04 EB01 EB22 EF01 EF27

Claims (16)

[Claims] An object has a surface layer in contact with the body of a seated person, a back layer positioned on the back side of the surface layer and supported by a support member made of a hard material, and between the surface layer and the back layer. Has an intermediate layer in at least a part thereof, and the surface layer, the back layer, and the intermediate layer are each made of a foam, and the foam constituting the surface layer is softer than the foam constituting the intermediate layer. The foam constituting the back layer has vibration characteristics different from those of the foam constituting the surface layer and the intermediate layer, and the layers are integrated by being chemically bonded at a boundary where they are in contact with each other. Cushion material characterized by having. 2. The cushioning material according to claim 1, wherein the hardness of the foam constituting the surface layer is 196.1 N / 314 cm ² or less. 3. The foam according to claim 1, wherein the foam constituting the intermediate layer has a hardness of 196.1 N / 314 cm ^2.
Cushion material characterized by exceeding. 4. The method according to claim 1, wherein:
A cushion material, wherein the back layer is made of a foam having higher vibration absorption than the surface layer and the intermediate layer. 5. The method according to claim 1, wherein:
The foam material constituting the back layer is a foam material having a resonance magnification of 3 times or less. 6. The method according to claim 1, wherein:
A cushion material, wherein the back layer is made of a foam having higher resilience than the surface layer and the intermediate layer. 7. The method according to claim 1, wherein:
The foam material constituting the back layer is a foam material having a rebound resilience of 70% or more. 8. The method according to claim 1, wherein:
The cushion material, wherein the surface layer, the intermediate layer, and the back layer are all made of a polyurethane resin foam. 9. The method according to claim 1, wherein:
The cushioning material has a central portion where a person sits, and both side portions formed to protrude on both left and right sides of the central portion,
The central part is the surface layer, the intermediate layer,
A cushioning material formed by laminating the back layer, wherein the both side portions are formed integrally extending from the back layer. 10. The cushioning material according to claim 1, wherein the cushioning member has a central portion for receiving a back of a person,
The center portion has two side portions protruding on both left and right sides of the center portion. The center portion is formed by laminating the surface layer, the intermediate layer, and the back layer in order from the front side. The cushioning material, wherein the side portion is formed integrally with the back layer. 11. A method of manufacturing a cushion material in which foam molding is performed using a lower mold and an upper mold, wherein the lower mold has a surface layer located on the front side and a back layer located on the back side of the cushion material. And a first cavity for molding a first central portion having an intermediate layer located between the surface layer and the back layer, the first cavity being disposed behind the first central portion and being the same as the back layer. A second cavity for molding a second central portion made of a material is formed, and a front and rear partition plate is provided between the first cavity and the second cavity. The mold has a bottom forming surface for forming the bottom of the cushion material. In performing the foam molding, the first cavity has a foaming property and becomes a foam. Sometimes the first raw material exhibiting the first physical property is injected At the same time, a third raw material having a foaming property and exhibiting third physical properties different from the first physical properties when formed into a foam is injected from above the first raw material. The cavity is filled with a second raw material having a foaming property and exhibiting a second physical property different from the first physical property and the third physical property when the foam is formed. The mold and the upper mold are closed, and a fluid port is formed between the bottom forming surface of the upper mold and the upper end of the front and rear partition plate to foam each of the raw materials. At the time of foaming, the first material flows forward so as to follow the flow at the tip of the flow, and at the time of foaming, the second material passes through the flow port from the second cavity into the first cavity. While flowing over the third raw material and covering the third raw material. Method of manufacturing a cushion material, characterized by comprising configured to continue to flow forward so as to follow the flow of the dynamic tip. 12. The lower mold according to claim 11, wherein:
Side cavities are formed for molding side portions disposed on both left and right sides of the cushion material, and
A first side partition plate is provided between the side cavity and the first cavity, and a second side partition plate is provided between the side cavity and the second cavity. And a method of manufacturing a cushioning material, wherein the cushioning material is also formed between the bottom forming surface of the upper die and the upper end of each of the side partition plates. 13. The method for manufacturing a cushion material according to claim 11, wherein the second central portion of the cushion material is cut off after the foam molding. 14. A method of manufacturing a cushion material in which foam molding is performed using a lower mold and an upper mold, wherein the lower mold has a surface layer located on the front side of the cushion material and a back layer located on the back side. A first cavity for forming a first central portion having an intermediate layer located between the surface layer and the back layer; and a material disposed behind the first cavity and having the same material as the back layer. A second cavity for molding a second central portion composed of the same; and an intermediate surface layer composed of the same material as the intermediate layer on the surface side of the cushion material between the first cavity and the second cavity. , A third cavity for molding a third central portion having the back layer is formed, and an intermediate partition plate is provided between the first cavity and the third cavity. The third key A front and rear partition plate is provided between the cavity and the second cavity, while the upper die is
It has a bottom forming surface for forming the bottom of the cushioning material.
Into the cavity, a first raw material having foaming properties and exhibiting the first physical property when formed into a foam is injected.
A second raw material having foaming properties and exhibiting second physical properties different from the first physical properties when formed into a foam is injected into the cavity, and foaming properties are injected into the third cavity. Having the first physical properties and the second physical properties
A third raw material exhibiting third physical properties different from the physical properties of the above is injected, and then the lower mold and the upper mold are closed, and the bottom forming surface of the upper mold and the upper end of the intermediate partition plate are closed. And an intermediate flow port between the bottom forming surface and the upper end of the front and rear partition plate.
Each of the raw materials is foamed, and the third raw material flows from the third cavity through the intermediate flow port into the first cavity at the time of the foaming, and covers the first raw material to cover the first raw material. The first raw material flows forward so as to follow the flow at the leading end of the raw material, and the second raw material flows from the second cavity through the flow port into the third cavity and the first cavity. A method of manufacturing a cushion material, wherein the cushioning material is configured to cover the third raw material and flow forward so as to follow the flow of the flow front end of the third raw material. 15. The lower mold according to claim 14, wherein:
Side cavities are formed for molding side portions disposed on both left and right sides of the cushion material, and
A first space is provided between the side cavity and the first cavity.
A side partition plate, a second side partition plate between the side cavity and the second cavity, and a third side partition plate between the side cavity and the third cavity. A method for manufacturing a cushioning material, characterized in that a flow port is also formed between the bottom forming surface of the upper die and the upper end of each of the side partition plates. 16. The method for manufacturing a cushion material according to claim 14, wherein the second central portion and the third central portion of the cushion material are cut off after the foam molding.