JP2003039446A - Method for producing foamed urethane molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable molding cost reduction, fitting work facilitation, etc. SOLUTION: After a urethane raw material U from a urethane injection head 25 is injected continuously on the upper surface of a release sheet 16 main body fed continuously from a sheet supply source 26, the sheet 16 is deformed into a sheet cylindrical body 18 and passed in a cylindrical guide member 28. In a process in which the cylindrical body 18 is moved in the guide member 28, a lengthy rod-shaped foamed urethane base material 14 the curing of which is advanced to be able to hold the shape of itself is molded continuously inside the cylindrical body 18. After the cylindrical body 18 is peeled off from the base material 14, the base material 14 is fitted to a molding fixture 35 while being deformed in a desired shape, and the curing is finished in this state, so that a foamed urethane molding with the shape fixed is produced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to molding a urethane foam base material which has been cured to such an extent that it can retain its shape from a urethane raw material, and then deforming the urethane foam base material into a desired shape. The present invention relates to a method for producing a urethane foam molded article in which the shape is fixed by setting the jig on the jig and terminating the curing in this state.

[0002]

2. Description of the Related Art For example, a passenger compartment door, an engine hood (bonnet), a trunk lid and the like (hereinafter collectively referred to as "door") are provided at an opening of a body of a passenger car so as to be opened and closed. The joining line between the inner edge of the opening of the body 11 and the outer edge of the door 12 has a structure shown in FIG.
As shown in FIG. 3, packing materials 10, 10 are provided on the body 11 side and / or the door 12 side to prevent rain leakage and the like. The packing material 10 has, for example, a round shape, a semicircular shape, an elliptical shape, a quadrangular shape or other irregular cross-sectional shape and is made of rubber or urethane foam base material or the like to which elasticity is appropriately given. The bent portion and the like are extended in a frame shape along the joint line in which they are continuously provided.

In order to implement the above-mentioned urethane foam base material having various sectional shapes as the packing material 10 for passenger cars, the following methods are appropriately adopted. For example, as shown in FIG. 8, the urethane foam base material 14 is molded into a shape along the joining line under the use of the foam molding die 13, so that the packing material 10 is formed of a single urethane foam base material 14. Forming method, as shown in FIG. 9, a urethane foam base material 14 of a required length formed into a substantially linear shape of a required length.
By connecting in series at the bent part etc. by secondary processing,
A method of forming the packing material 10 with a plurality of urethane foam base materials 14, as shown in FIG. 10, forcing the long urethane foam base material 14 formed in a linear shape along the joining line when attaching it to a door or a body. A method of forming the packing material 10 with a single urethane foam base material 14 by bending or bending the same is used.

[0004]

By the way, in each of the above methods (1) to (4), the following drawbacks and problems are inherent when the packing material 10 is formed from each urethane foam base material 14. In the first case, since the urethane foam base material 14 is molded into a desired shape by using the foam molding die 13, there is an advantage that the texture of the packing material 10 and the mounting workability are improved, but the foam molding die is used. The manufacturing cost of No. 13 increases, which causes an increase in molding cost. However, since it is a batch system, there are inherent problems such as low molding efficiency and poor productivity. In other cases, each urethane foam base material 14
Since joining work is required, the manufacturing cost is increased due to an increase in the number of working steps, while there are problems such as insufficient strength of the joining portion and deterioration of texture. Further, in the case where the urethane foam base material 14 is forcibly deformed at the curved portion or the bent portion of the joining line, the elastic resilience acts on the urethane foam base material 14 to deteriorate the mounting workability and There was a problem that it could not be properly extended along the line.

[0005]

SUMMARY OF THE INVENTION The present invention has been proposed in order to preferably solve the above-mentioned problems. After molding a urethane foam base material which has been cured to such an extent that the urethane raw material can retain its own shape, Set the urethane foam base material into the required shape while deforming it to the required shape, finish the cure in this state, and manufacture the urethane foam molded product in which the shape has been fixed. It is an object of the present invention to provide a method for producing a urethane foam molded article that enables the above.

[0006]

SUMMARY OF THE INVENTION In order to solve the above problems and achieve an intended object, the present invention is directed to urethane from a urethane pouring head on the upper surface of the main body of a release sheet continuously fed from a sheet supply source. The raw material is continuously injected, the main body of the release sheet is passed through the inside of the tubular guide member, and both longitudinal end edges of the release sheet are shaped like a palm from a slit opened in the longitudinal direction of the tubular guide member. To form a sheet tubular body, and accelerate the reaction of the urethane raw material in the process of moving the inside of the tubular guide member where the sheet tubular body is heated, and the sheet tubular body itself From the urethane foam base material that has passed through the tubular guide member and is continuously molded, a urethane foam base material in the form of a long bar that has been cured to such an extent that the shape can be retained is formed into the sheet tubular body. Formed The peeling sheet was peeled off, and the urethane foam base material after peeling was set on a molding jig while deforming the foamed urethane base material into a required shape. In this state, the cure of the urethane foam base material was completed to fix the shape. It is characterized in that a urethane foam molded product is manufactured.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION Next, a method for producing a urethane foam molded article according to the present invention will be described below with reference to the accompanying drawings with reference to preferred embodiments.

First, a production line capable of suitably carrying out the method for producing a urethane foam molded article of the present invention will be schematically described. FIG. 1 is a side view schematically showing a production line capable of suitably carrying out the method for producing a urethane foam molded article of the present invention. The manufacturing line 20 includes a first molding step unit 21 for continuously molding a long-rod-shaped urethane foam base material 14 which has been cured to the extent that the urethane raw material U can be reacted to maintain its shape. Foamed urethane base material 14
The second molding process section 22 for molding the urethane foam molded product 15 in which the shape is fixed by curving or bending at a required position in the longitudinal direction and terminating the curing of the base material 14 in this state. It is configured to

The first molding process section 21 includes a release sheet 1
6 and a supply unit 23 for supplying the urethane raw material U, and a base material for forming a long-rod-shaped urethane foam base material 14 which has progressed to such an extent that the urethane raw material U is allowed to react to maintain its shape. And a molding section 24. That is, the release sheet 16 is continuously fed out at a constant speed toward the base material molding section 24, and the urethane raw material U is supplied to the upper surface of the release sheet 16 via the urethane pouring head 25, thereby forming a cylinder. The long rod-shaped urethane foam base material 14 is continuously molded inside the release sheet 16 (sheet cylindrical body 18) that is molded into a shape.

The supply section 23 is a delivery roller 27 for continuously delivering the release sheet 16 wound around the sheet supply source 26 toward the base material molding section 24 at a constant speed, and the release sheet 16. The urethane pouring head 25 for pouring the urethane raw material U continuously is provided on the upper surface. Then, the release sheet 16 continuously fed from the sheet supply source 26 by the feeding roller 27 and traveling horizontally is
Although it has a flat shape when passing through the payout roller 27, the base material molding section 2 disposed on the downstream side in the sheet feeding direction thereof.
When passing through the inside of the tubular guide member 28 of No. 4, the two end edges 17, 17 in the longitudinal direction abut in a palm shape and are formed into a tubular shape to form a tubular sheet body 18. By adjusting the delivery speed of the release sheet 16 driven by the feeding roller 27 and the time unit amount of the urethane raw material U from the urethane pouring head 25, the urethane is supplied to the base material molding unit 24. The quantity is determined.

The urethane raw material U immediately before being poured onto the upper surface of the release sheet 16 is mechanically stirred by mixing a gas such as an inert gas into a foam raw material made of, for example, isocyanate and polyol. What is obtained by a so-called mechanical floss method or the like is used. The urethane raw material U made by the mechanical floss method is in a state of being finely foamed in advance. It should be noted that instead of the urethane raw material U obtained by the mechanical froth method, for example, a foam raw material made of, for example, isocyanate and polyol, in which a foaming agent is mixed and which is in a non-foamed state, may be used. Good. In the latter case, the bubbling reaction proceeds in the tubular body 18 after pouring out into the opening of the tubular body 18.

As shown in FIG. 2, the base material molding section 24 is provided with a cylindrical guide member 28 of a required length which extends horizontally along the sheet feeding direction, and above the guide member 28. A plurality of belt-shaped feeding members 30 facing each other
It consists of and. The cylindrical guide member 28 is configured as a pipe-shaped cylindrical body required to define the external shape of the urethane foam base material 14, and has upper end wall surfaces thereof at both end edges 17, 17 in the longitudinal direction of the release sheet 16. A slit 29 having a small width is formed to allow the passage of. Therefore, the release sheet 16 delivered from the supply section 23 has its sheet main body portion pass through the inside of the tubular guide member 28, and both end edges 1 in the longitudinal direction of the sheet 16.
7 and 17 are outwardly extended from the slit 29 in a palm shape, whereby the sheet tubular body 18 is molded. Further, as shown in FIG. 4, the both end edge portions 17, 17 extending outward from the slit 29 in a palmar shape have the belts 31, 31 of the belt-shaped feeding members 30, 30 facing each other.
It is pinched by 31 and pulled downstream in the sheet feeding direction. A plurality of belt-shaped feed members 30 are arranged along the tubular guide member 28 at a required interval,
It is driven at a constant speed by a driving device such as a motor (not shown).

A heating member 32 typified by an electric heater is mounted on the outer side of the tubular guide member 28, whereby the tubular guide member 28 is heated to an appropriate temperature to promote the reaction of the urethane raw material U. It is like this. Therefore, the urethane raw material U inside the sheet tubular body 18 that moves at a constant speed by driving the belt-shaped feed members 30, 30 is
As the sheet tubular body 18 approaches the downstream outlet of the tubular guide member 28, the reaction is promoted, and the sheet tubular body 18
The urethane foam base material 14 that has been cured to such an extent that the shape of the urethane foam base material 14 can be retained therein is formed inside. At this point, the urethane foam base material 14 includes the release sheet 16 that forms the sheet tubular body 18, and
Even if it is peeled off from the outer surface of the, its shape does not collapse.

The release sheet 16 is composed of a paper sheet or a resin sheet coated with a release component such as a silicone resin on at least the side in contact with the urethane raw material U.
As a result, the release sheet 16 can be easily released from the urethane foam base material 14 formed inside the sheet tubular body 18. Such a release sheet 16 is required when the urethane foam base material 14 is molded in the first molding process section 21, and after the molding of the urethane foam base material 14 is completed.
After (passing through the tubular guide member 28), it is peeled from the urethane foam base material 14 and wound up and collected by the sheet collecting portion 33 provided on the downstream side of the cylindrical guide member 28 (FIG. 1).

The second molding step section 22 is a molding jig 35 for setting the urethane foam base material 14 molded in the first molding step section 21 in a winding shape, and this molding jig 35. Foamed urethane base material 14 set in a roll
It is composed of a forming furnace 36 for heating the. Of these, as shown in FIG. 3, the molding jig 35 has a rectangular tubular shape that is rotatably and slidably arranged on a horizontal support shaft 38 of a support base 37. In the state where the curing has progressed to the extent that it can retain its own shape in
The urethane foam base material 14 formed in (the state where the curing is not completed) is wound around the outer peripheral surface in a spiral manner. As a result, the urethane base material 14 is sequentially bent at a required position in the longitudinal direction and sequentially deformed into a rectangular frame shape.

Then, the urethane foam base material 14 which is spirally wound and set on the molding jig 35 and flexibly deformed at a predetermined position in the longitudinal direction is used for molding as shown in FIG. The jig 35 and the jig 35 are housed in a molding furnace 36 whose temperature is controlled to a predetermined temperature, and curing is promoted. This forming furnace 3
In 6, the temperature inside the furnace can be adjusted by a heating member 39 including a heating heater and the like. That is, the second molding process unit 2
2 is a urethane foam base material 1 housed in the molding furnace 36.
4 is a step of so-called "curing" by continuously heating 4 at a predetermined temperature for a predetermined time, whereby the urethane foam group wound and set on the molding jig 35 while being flexibly deformed. In this state, the material 14 is completely cured, and the urethane foam molded article 15 having the above-described shape is fixed.
Is manufactured. Here, when the urethane foam base material 14 is cured, it is desirable to mount the support material 40 that supports the bent portion of the urethane foam base material 14 from the outside.

The molding jig 35 shown in the embodiment is used.
Is just an example of a rectangular tubular shape for manufacturing the urethane foam molded product 15 having a rectangular frame shape, and the shape of the molding jig 35 is appropriately determined based on the final shape of the urethane foam molded product 15. It is set.

Next, a method of manufacturing a urethane foam molded article, which is carried out by the manufacturing line 20 having the above-described structure, will be specifically described.

In a state where the feeding roller 27 and the belt-shaped feeding members 30 are synchronously operated at a constant speed,
The release sheet 16 delivered from the sheet supply source 26 of the supply unit 23 is exposed to the delivery roller 27. Then, the release sheet 16 that has passed through the feeding roller 27 is provided with the edge portions 1 at both ends thereof.
7 and 17 are brought into contact with each other in the shape of a palm to form a sheet tubular body 18, the main body of the release sheet 16 is passed inside the tubular guide member 28, and both end edges 1 in the longitudinal direction are formed.
7 and 17 are made to extend from the slit 29 of the tubular guide member 28 in a palm shape and faced between the belt-shaped feed members 30 and 30. Further, the sheet tubular body 18 drawn outward from the downstream end of the tubular guide member 28 is opened from the gathered state of both edge portions 17 and 17 to the original flat state, and then sequentially wound around the sheet collecting section 33. Collect and collect. As a result, the flat release sheet 16 delivered from the sheet supply source 26 is fed by the belt-shaped feed members 30 and 30.
After being transformed into the sheet tubular body 18 and passing through the tubular guide member 28, it is again transformed into a planar shape and is collected by the sheet collecting unit 33.

When the release sheet 16 is continuously fed at a constant speed, the urethane raw material U is fed from the urethane pouring head 25 installed above the supply section 23.
Is poured onto the upper surface of the release sheet 16 before being transformed into the sheet tubular body 18. At this time, by continuously pouring the urethane raw material U from the urethane pouring head 25, the urethane raw material U is continuously supplied to the upper surface of the release sheet 16 in a continuous streak shape.

The release sheet 16 on which the urethane raw material U is placed is gradually deformed into a sheet tubular body 18 containing the urethane raw material U inside and moved into the tubular guide member 28 as it moves downstream. To do. Then, since the tubular guide member 28 is heated by the heating member 32,
When the reaction of the urethane raw material U in the sheet tubular body 18 is promoted and the tubular guide member 28 approaches the downstream end,
The urethane foam base material 14, which has been cured to such an extent that it can maintain its shape, is continuously molded inside the sheet tubular body 18. Then, the tubular guide member 28
The urethane foam base material 14 that passes through and reaches the downstream side.
The release sheet 16 from which the sheet tubular body 18 was formed
Are peeled off and sequentially collected in the sheet collecting unit 33.
The urethane foam base material 14 is sequentially exposed on the downstream side of the base material molding portion 24.

The urethane foam base material 14 molded in the first molding process section 21 is spirally wound and set around the outer peripheral surface of the molding jig 35, and at this time, it is bent and deformed at a required position in the longitudinal direction. Then, it is transformed into a rectangular frame having a required dimension. Then, the molding jig 35, on which the urethane foam base material 14 is wound and set, is housed in the molding furnace 36 whose temperature is controlled to a predetermined temperature by the heating member 39 for a predetermined time, whereby the urethane foam base material 14 Finish the cure. The conditions for properly curing the urethane foam base material 14 are changed depending on the thickness and length of the base material 14, but in the case of the example, the furnace temperature is 60 ° C. The heating time is about 2 hours or more (however, the heating time can be changed depending on the temperature in the furnace). Further, although it is possible to complete the cure even at room temperature, it takes a considerable time to complete the cure. When the urethane foam base material 14 is cured, as described above, by mounting the support material 40 on the bent portion of the base material 14, the molding accuracy of the urethane foam molding 15 can be improved. .

The urethane foam molded article 15 obtained by curing the urethane foam base material 14 is removed from the molding jig 35 and then cut at a required position to form a rectangular frame shape. Here, since the shape of the urethane foam molded article 15 finally molded is fixed, the urethane foam molded article 15 does not deform even if the hand is released.

As described above, in the method for manufacturing the urethane foam molded article of the present embodiment, the urethane raw material U is reacted inside the sheet tubular body 18 made of the release sheet 16 in the first molding process section 21 to form the shape of itself. In the second molding step 22, the long rod-shaped urethane foam base material 14, which is continuously molded in a state in which the curing has progressed to such an extent that it can be held, is deformed at a required position in the longitudinal direction. It is possible to suitably mold the urethane foam molded product 15 in which the above-mentioned shape is fixed, by setting it to 35 and terminating the curing in this state. Therefore, by setting the molding jig 35 to a shape that can be set while deforming the urethane foam base material 14 obtained in the first molding step unit 21 into a desired final shape, the second molding step is performed. The urethane foam molded product 15 obtained in the part 22 is preferably formed in a state where the desired final shape is fixed, and the molding cost can be reduced with the rationalization of the molding work. Further, since the urethane foam molded article 15 obtained by the manufacturing method of the embodiment is already in a desired shape at the time of molding, it is possible to facilitate and rationalize the mounting work, and various shapes can be achieved. Packing material,
It can be suitably implemented as a cushioning material, a sealing material and the like.

By changing the form and shape of the molding jig 35, it is possible to mold urethane foam molded products 15 of various forms and shapes. For example, if the molding jig 35 is a cylindrical body, a circular ring-shaped urethane foam molded product can be molded. Further, in the above-described embodiment, the form in which the urethane foam base material 14 is continuously wound spirally around the molding jig 35 to form a plurality of urethane foam molded products 15 of the same shape is exemplified. The urethane foam base material 14 may be wound around the jig 35 only once to mold the urethane foam molded articles 15 one by one.

In the case of molding a urethane foam molded article 15 in the shape of a rod with a required length having a bent portion 42 at an appropriate portion, as shown in FIG. 6, instead of the frame shape (ring shape),
A molding jig 35 including a first molding plate 43 having a convex portion 44 and a second molding plate 45 having a concave portion 46 is used. That is, after the urethane foam base material 14 obtained in the first molding process section 21 is cut into a required length, the curing is finished while being deformed into a required shape by the molding jig 35, so that the bent portion 42 is removed. It is possible to manufacture the urethane foam molded article 15 in which the required shape is fixed.

Further, in the above-mentioned embodiment, the case where the urethane foam base material 14 and the urethane foam molded product 15 having a circular cross section are molded by making the inside of the cylindrical guide member 28 in the base material molding portion 24 into a circular cross section. Although illustrated, by changing the inner cross-sectional shape of the tubular guide member 28 to a semicircular shape, an elliptical shape, a rectangular shape, etc., the urethane foam base material 14 and the urethane foam molded article 15 having a cross-sectional shape based on this are molded. It becomes possible.

The usage of the urethane foam molded product obtained by the method for manufacturing a urethane foam molded product of the present application is not limited to the packing material described above, and various uses such as a cushioning material and a sealing material are possible. It can be used.

[0029]

As described above, according to the method for producing a urethane foam molded article according to the present invention, the reaction of the urethane raw material is promoted inside the sheet cylindrical body made of the release sheet to maintain the shape of itself. A long rod-shaped urethane foam base material that is continuously obtained in a state where curing has progressed to the extent that
Before the base material is cured, the base material is set on a molding jig while being deformed at a required position in the longitudinal direction, and the cure of the foamed urethane base material is terminated in this state to form the foamed urethane foam with the fixed shape. A beneficial effect that a product can be suitably manufactured is exhibited. Therefore, by setting the shape and form of the molding jig, urethane foam molded products having various shapes and forms can be efficiently manufactured, and thus the molding cost can be reduced and the mounting work can be facilitated. Further, depending on the shape and form of the molding jig, a plurality of urethane foam molded products having the same shape can be molded at the same time, or urethane foam molded products of a required length can be molded one by one.

[Brief description of drawings]

FIG. 1 is a schematic side view of a production line on which a method for producing a urethane foam molded article according to the present invention can be suitably implemented.

FIG. 2 is a schematic perspective view showing a first molding step in the production line shown in FIG. 1 in a state where a urethane foam base material that has been cured to such an extent that the shape thereof can be retained is continuously molded. .

3 is a schematic perspective view showing a second molding step in the production line shown in FIG. 1 in a state in which the urethane foam base material molded in the first molding step is spirally wound around a molding jig. is there.

4 is a sectional view taken along line IV-IV in FIG.

FIG. 5 is a cross-sectional view showing a state where a urethane foam molded article having a fixed shape in a rectangular frame is manufactured by finishing the curing of the urethane foam base material wound and set on a molding jig.

FIG. 6 shows a state in which a urethane foam molded article having a fixed concave portion at a proper portion is fixed by terminating curing while deforming a rod-shaped urethane foam base material cut into a required length by a molding jig. FIG.

FIG. 7 is a schematic perspective view showing an example of a urethane foam molded product implemented as a packing material arranged at a joining line between a body opening of a passenger car and a door.

8 is a schematic perspective view for explaining a method of forming the packing material shown in FIG. 7 by molding a urethane foam base material into a required shape using a foam molding die.

9 is a schematic perspective view for explaining a method of forming a packing material shown in FIG. 7 by joining a plurality of urethane foam base materials formed in a substantially linear shape having a required length by secondary processing.

10 is a front view for explaining a method of forming the packing material shown in FIG. 7 by bending and bending a long urethane foam base material formed in a linear shape.

[Explanation of symbols]

14 Urethane foam base material 15 Polyurethane foam molding 16 Release sheet 17 Edge 18-sheet cylinder 25 Urethane pouring head 26 sheet supply source 28 Cylindrical guide member 29 slits 35 Molding jig U Urethane raw material

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Kentaro Sakai             Aichi Prefecture Anjo City Imaikecho 3 1-336 Stock             Inoac Corporation Anjo Business             In-house F-term (reference) 4F204 AA42 AG14 AG20 EA01 EB02                       EF01 EF27 EK06 EK13 EK17                       EL04 EW06 EW23

Claims (3)

[Claims] 1. A urethane pouring head (25) on an upper surface of a main body of a release sheet (16) continuously fed from a sheet supply source (26).
The urethane raw material (U) from (1) is continuously injected, and the main body of the release sheet (16) is passed inside the tubular guide member (28), and the longitudinal end edges of the release sheet (16) ( (17, 17) is formed into a sheet tubular body (18) by extending in a palm shape from a slit (29) opened in the longitudinal direction of the tubular guide member (28), and the sheet tubular body (18) is heated. The tubular guide member (2
8) Foam in the form of a long rod in which the reaction of the urethane raw material (U) is promoted in the process of moving inside, and the curing has progressed to such an extent that the shape of the sheet tubular body (18) can be retained inside. The urethane base material (14) was continuously molded, and the sheet tubular body (18) was formed from the urethane foam base material (14) coming through the tubular guide member (28). The release sheet (16) is peeled off, and the urethane foam base material (14) after peeling is set on a molding jig (35) while deforming it into a required shape, and in this state, the urethane foam base material (14) is A method for producing a urethane foam molded article, characterized in that a urethane foam molded article (15) in which the shape has been fixed is produced by terminating curing. 2. A jig for molding the urethane foam base material (14), which has been cured to such an extent that it can maintain its own shape.
A plurality of the urethane foam molded articles (15) having the shape fixed can be simultaneously produced by successively winding the spiral shape around the outer peripheral surface of (35) and terminating the curing while deforming the shape. Item 2. A method for producing a urethane foam molded article according to item 1. 3. The urethane foam base material (14), which has been cured to such an extent that it can retain its own shape, is cut into a required length after being cut into a required length by the molding jig (35). The method for producing a urethane foam molded article according to claim 1, wherein the urethane foam molded article (15) in which the shape is fixed can be manufactured by terminating the step.