JP2003153707A - Production method of sheet cushion pad with hook-and- loop fastener - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a production method of a sheet cushion pad with a hook- and-loop fastener which can reduce a drop in the rate of the generation of defective products by preventing slipping of the hook-and-loop fastener, the peeling of some of foam molded bodies and others in the opening of dies. SOLUTION: In the production method of a sheet cushion pad with the hook- and-loop fastener, the hook-and-loop fastener 23 is housed into a recessed groove 24a of a fastener support member 24 fixed on a lower die 12 and a foaming resin material is injected into molding dies 10A and 10B to be molded being foamed. The opening of the die is performed so that the hook-and-loop fastener 23 solidified integrally on the foam molded body 20 is pulled out of the recessed groove 24a against a resistance to obtain the sheet cushion pad with the hook- and-loop fastener 23 integrally solidified on the surface of the foam molded body 20. The fastener support member is set in such a shape that the pull-out resistance can be regulated below a fixed value to house the hook-and-loop fastener into the recessed groove of the fastener support member.

Description

Detailed Description of the Invention

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is mainly used for vehicle seats such as automobiles, and is composed of a foamed molded product of a foamable resin material such as urethane, and a skin material for covering the surface of the foamed molded product. The present invention relates to a method for manufacturing a seat cushion pad with surface fasteners, wherein a surface fastener for fixedly and removably joining the foam molded body is integrally fixed to the surface of the foam molded body during molding.

2. Description of the Related Art A molding die used in a method for manufacturing such a seat cushion pad with hook-and-loop fastener is used for manufacturing a seat cushion pad for a seat which is installed in a driver's cab of a vehicle and holds the lower half of the operator. Mold for splitting and a mold for splitting used to manufacture a backrest seat cushion pad called a backrest that is tiltably installed at the rear of the seat cushion for the seat and holds the upper body of the operator. There is. FIG. 4 is a cross-sectional view of a split type forming die used for manufacturing a seat cushion pad for a seat among the above, and the split type forming die 10A includes an upper die 11 and a lower die 12. , The lower molds 11 and 12 are formed in the lower mold 12 at the outer periphery of both molds 11 and 12, and the cavity 1 has an upward opening.
Horizontal fulcrum shaft 1 set higher than the upper opening of 3
The mold can be opened and closed by relatively rotating around 4. FIG. 5 is a cross-sectional view of a three-piece type forming die used for manufacturing a backrest seat cushion pad with hook-and-loop fasteners. The three-piece type forming die 10B has a core die 15 attached thereto. It consists of an upper mold 11 and a lower mold 12.
The mold can be opened and closed by relatively rotating it around a horizontal fulcrum shaft 14 set at a position higher than the upper opening of the upward opening cavity 13 formed in 2. On the other hand, as a form in which the surface fastener is integrally fixed to the surface of the foamed molded body that constitutes the seat cushion body,
As shown by phantom lines in FIG. 6, in a posture along the longitudinal direction of the foamed molded body 20 in the vicinity of each boundary between the center support portion 21 of the foamed molded body 20 and the side support portions 22, 22 located on both sides in the width direction thereof. In the case of so-called vertical pulling specification in which the surface fastener 23 is inserted and fixed integrally, and as shown by the solid line in FIG. 6, the surface fastener 23 is in the posture along the width direction of the foamed molded body 20 at the intermediate portion of the center support portion 20. There is a case of so-called horizontal pulling specification in which is inserted and fixed integrally. 4 and 5 are conventional seat cushions with hook-and-loop fasteners in which the hook-and-loop fasteners 23 are integrally fixed by the above-mentioned lateral pulling specification by using the above-mentioned two-half type mold 10A or three-type mold 10B. 7 shows a pad manufacturing state, in which a convex surface fastener 23 integrally fixed to the foam molding 20 side and a concave shape attached to the skin material side are provided at predetermined positions of the lower mold 12 in the molding die 10A or 10B. A ridge 12a is provided which forms a slit-shaped groove for engaging with a surface fastener (not shown).
A fastener support member 24 having a groove-shaped cross section is fixed to the shaft with bolts or the like. The groove 2 of the fastener support member 24
As shown in FIG. 7, a plurality of engaging elements 23b are arranged in a protruding state on one surface of the strip-shaped base portion 23a in the inside of 4a, and a foam molding is formed on the other surface. Two
A convex surface fastener 23 formed by projecting an anchor portion 23c embedded in 0 has two end edges of a belt-shaped base portion 23a with a concave groove 2
It is elastically fitted between the inner surfaces of both side walls 24b, 24b facing each other with 4a in between, and the tip ends of the plurality of engaging elements 23b are housed so as to abut the bottom surface of the concave groove 24a. In this stored state, the cavity 1 of the molding die 10A or 10B
By injecting a liquid foamable resin material such as an undiluted urethane solution into 3 and foaming and curing it, a foamed molded body 20 having a predetermined shape
Is molded. After molding, the upper mold 11 and the lower mold 12 are fulcrum shaft 1
By relatively rotating around 4 and opening the mold,
A seat cushion pad in which convex surface fasteners are integrally fixed to the foam molded body 20 in a lateral pulling specification through the anchor portion 23c embedded in the foam molded body 20 is manufactured.

By the way, in the conventional method for manufacturing a seat cushion pad with hook and loop fastener as described above, it is integrally fixed to the surface of the foamed molded body 20 when the mold is opened after molding. The surface fastener 23 draws out from the concave groove 24a of the fastener support member 24 fixed to the lower die 12 while drawing an arc-shaped rotation locus R around the fulcrum shaft 14. Therefore, the groove 24
The side edges of the strip-shaped base portion 23a of the surface fastener 23 elastically fitted between the inner surfaces of the opposite side walls 24b, 24b of the a are the side walls 24b, 24b of the concave groove 24a of the fastener support member 24.
Rubbing strongly on one of the inner surfaces of the foam fastener 23, and as a result, the surface fastener 23 falls off from the foam molded body 23, or a part of the foam molded body 20 in which the anchor portion 23c is embedded peels off together with the surface fastener 23. , Product (seat cushion pad) defective. In particular, in the case of the above-described lateral pulling specification, one side wall 24 of the concave groove 24a in the surface fastener 23 and the fastener support member 24 at the time of mold opening.
Since the inner surface b is strongly rubbed in the range over the entire length thereof, the pull-out resistance is so large that the hook-and-loop fasteners 23 fall off and some of the foamed molded bodies 20 fall off,
There was a problem that the incidence of defective products was extremely high. The present invention has been made in view of the above-mentioned circumstances, and by only making a simple device for the attachment form or shape of the fastener support member, it is possible to prevent the surface fastener from falling off or peeling off a part of the foamed molded article when the mold is opened. An object of the present invention is to provide a method for manufacturing a seat cushion pad with hook-and-loop fasteners, which can be prevented to significantly reduce the incidence of defective products.

In order to achieve the above object, a method of manufacturing a seat cushion pad with hook-and-loop fasteners according to the present invention comprises a fastener support member having a grooved cross section at a predetermined position of a lower die of a forming die. Fix, in the groove of the fastener support member, a surface fastener formed by a plurality of engaging elements projecting on one surface of the strip-shaped base is stored so that the engaging element abuts the groove bottom surface, In this housed state, inject a foamable resin material into the mold to perform foam molding, and then the surface fastener integrally fixed to the foam molded body is pulled out from the concave groove while being pulled out while resisting resistance. A method for manufacturing a seat cushion pad with hook-and-loop fasteners, wherein the hook-and-loop fastener is integrally opened on the surface of the foamed molded article to obtain a seat cushion pad. The possible forms in a state of setting the fastener support member is configured to house the hook and loop fastener in the groove of the fastener supporting member. According to the present invention having the above characteristics, with the mold opening operation after foam molding,
The surface fastener fixed to the surface of the foam molded product draws a circular arc-shaped rotation locus around a predetermined center of rotation, and the pull-out resistance when moving out of the concave groove of the fastener support member fixed to the lower mold is constant. Since it can be regulated below the value, conventional defects, i.e., when the mold is opened, the strip-shaped base portion of the surface fastener is strongly rubbed against the inner surface of the opposing side wall of the groove in the fastener supporting member, and the slip-out resistance exceeds a certain value, and as a result, It is possible to avoid the problem that the surface fastener falls off from the foam molded article, or a part of the foam molded article peels off together with the surface fastener, and the surface fastener is firmly fixed integrally at a predetermined position of the foam molded article. The same product (seat cushion pad with hook-and-loop fastener) can be manufactured with high yield. In the method for manufacturing a seat cushion pad with hook-and-loop fastener according to the present invention described above, as the molding die, an upper die and a lower die, or an upper die and a lower die to which a core die is attached are set on the outer peripheral portions of both die. It is also possible to use a molding die that can be opened and closed by relative rotation about the fulcrum axis, and to open the die by relatively rotating the upper die and the lower die around the fulcrum axis. According to this means, the surface fastener fixed to the surface of the foam-molded article is drawn in the arc-shaped rotation locus around the fulcrum axis with the mold opening operation after foam-molding, and the fastener fixed to the lower mold. It is possible to regulate the slip-out resistance when moving out of the concave groove of the support member to a fixed value or less, avoiding the above-mentioned conventional inconvenience, and fixing the surface fastener firmly to a predetermined position of the foam molded body. The same product (seat cushion pad with hook-and-loop fastener) can be manufactured with high yield. In the above-described method for manufacturing a seat cushion pad with hook-and-loop fastener according to the present invention, as a mode in which the pull-out resistance can be regulated to a certain value or less,
As described in 1, the both side walls facing each other across the groove are substantially along the rotation trajectory of the rotation of the strip base end edges of the surface fastener at the time of mold opening, and the entire fastener support member is formed into the reference surface of the lower mold in the molding die. With respect to a mode in which the lower mold is inclined and fixed at a predetermined position, or both side walls facing each other across the groove are perpendicular to the reference plane in the molding die. Of the above-mentioned both side walls of the fastener support member fixed in a predetermined position in the lower mold,
A form in which the inner surface of the upper half of the side wall on the side far from the center of rotation of the surface fastener at the time of mold opening is formed into a curved surface that substantially follows the rotation trajectory of both end edges of the belt-shaped base of the surface fastener, or
According to a sixth aspect of the present invention, the withdrawal resistance can be regulated to a certain value or less so that the lower mold is predetermined in a state where both side walls facing each other across the concave groove are perpendicular to the reference surface of the molding mold. Either of the forms in which the above-mentioned both side walls of the fastener supporting member fixed in the position are set to the minimum height dimension within a range sufficient to elastically fit and hold the surface fastener accommodated in the concave groove may be adopted. Of the above-mentioned forms, when adopting a form in which the fastener support member is fixed to the lower mold in an inclined posture as described in claim 3, the surface fastener is set in the concave groove of the fastener support member when the surface fastener is set. Since it can be inserted deeply into the mold to hold it firmly and elastically, the surface fastener moves unexpectedly when the foamed resin material is injected into the molding die or when it foams and hardens, or the foamed resin material is inserted into the groove. It is possible to reliably prevent the surface fasteners from rising and the floating fasteners to rise, and it is possible to improve the non-defective product rate. Further, when adopting the configuration according to claim 5 or 6, it is extremely effective for the fastener support member. A simple structure improvement is sufficient, and there is no need to provide an inclined surface for fixing the fastener support member to the lower mold as in the case where the fastener support member is fixed to the lower mold in an inclined posture, and the cost of the molding die is reduced. Yasu . Further, in the method for manufacturing a seat cushion pad with hook-and-loop fastener according to the present invention, as described in claim 7, the hook-and-loop fastener is integrally fixed to the foam molded article in a posture along the width direction of the foam molded article. Although it can be effectively applied to the case of horizontal pulling specifications, it is also effective to prevent the surface fasteners from falling out even when applied to the vertical pulling specifications.

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is an enlarged cross-sectional view of essential parts showing a first embodiment of a molding die used in a method for manufacturing a seat cushion pad with hook-and-loop fastener according to the present invention. This mold has a two-part type and a three-part type, and since the basic configurations thereof are the same as those shown in FIGS. 4 and 5, respectively, they are not shown again here. Further, the manufacturing process of the seat cushion pad with the surface fastener when the surface fastener 23 is integrally fixed by the horizontal pulling specification by using the split mold 10A or the split mold 10B is also a column of the conventional art. Since it is the same as the one described, detailed description thereof will be omitted, and only the configuration of a main part different from the prior art and the operation of the part at the time of mold opening will be described. In FIG. 1, a molding die 10A or 10B
Ridge portion 1 provided at a predetermined position of the lower die 12 in
The upper surface 12b of 2a is formed into an inclined surface such that the protruding height into the cavity 13 gradually increases toward the mold opening fulcrum shaft 14 side. The inclined surface 12b is provided with fasteners having a groove-shaped cross section by bolts or the like. By fixing the member 24, the fastener supporting member 24 is entirely fixed to the reference surface 12 of the lower mold 12.
It is attached at an angle of θ (preferably around 20 °) with respect to s, whereby both side walls 24 facing each other with the concave groove 24a in the fastener supporting member 24 interposed therebetween.
b and 24b are set so as to substantially follow the arcuate rotation locus R of both side edges of the strip-shaped base portion 23a of the surface fastener 23 when the mold is opened. In the case of the first embodiment in which the predetermined foam molding is performed with the fastener supporting member 24 fixed to the reference surface 12s of the lower mold 12 as described above, the mold opening operation after foam molding is performed. Accordingly, the foam molded body 20
The surface fastener 23 fixed to the surface of the mold is the molding die 10A.
Alternatively, while drawing a circular arc-shaped rotation locus R around the fulcrum shaft 14 (corresponding to the center of rotation of the surface fastener) of 10B, the fastener support member 24 fixed to the lower die 12 moves out of the concave groove 24a. The escape resistance at this time is a constant value,
That is, since the surface fastener 23 is regulated to be equal to or less than the withdrawal resistance value when elastically fitted in the concave groove 24a of the fastener support member 24, the conventional defect, that is, the belt-shaped base portion 23a of the surface fastener 23 when the die is opened is used. Support member 2
4, the inner surfaces of the opposite side walls 24b, 24b of the concave groove 24a are strongly rubbed, and as a result, the surface fastener 23 is formed into the foamed molded body 2.
It is possible to avoid the problem that the foam fastener 20 falls off from 0 or a part of the foam molded article 20 is peeled off together with the hook fastener 23, and the fastener fastener 23 is firmly and securely integrally fixed at a predetermined position of the foam molded article 20. Moreover, it is possible to manufacture a desired product (seat cushion pad with hook-and-loop fastener) with good yield. FIG. 2 is an enlarged cross-sectional view of a main part showing a second embodiment of a molding die used in the method for manufacturing a seat cushion pad with hook-and-loop fastener according to the present invention. In the second embodiment, the fastener support member 24 is omitted. , Fixed to the horizontal upper surface 12b of the ridge 12a of the lower mold 12 with both side walls 24b, 24b of the fastener supporting member 24 facing each other with the concave groove 24a interposed therebetween being perpendicular to the reference surface 12s of the lower mold 12. On the other hand, of the both side walls 24b, 24b of the fastener support member 24, the inner surface 24b1 of the upper half of the side wall 24b on the side far from the fulcrum shaft 14 is attached to the surface fastener 23.
The belt base 23a is formed into a curved surface that substantially follows the rotation locus R of both end edges of the belt base 23a, and the withdrawal resistance when the surface fastener 23 moves out of the concave groove 24a of the fastener support member 24 is regulated to a certain value or less. It is set in a different form. FIG. 3 is an enlarged cross-sectional view of an essential part showing a third embodiment of a molding die used in the method for manufacturing a seat cushion pad with hook-and-loop fastener according to the present invention.
In the embodiment, the fastener supporting member 24 is provided on both side walls 2 facing each other with the concave groove 24a in the fastener supporting member 24 interposed therebetween.
4b and 24b are fixed to the horizontal upper surface 12b of the protrusion 12a of the lower mold 12 in a state in which they are perpendicular to the reference surface 12s of the lower mold 12, while the both side walls 24 of the fastener support member 24 are
b and 24b are surface fasteners 2 housed in the concave groove 24a.
3 is set to a minimum height dimension h within a range sufficient for elastically fitting and holding, so that the withdrawal resistance when the surface fastener 23 comes out of the concave groove 24a of the fastener support member 24 and moves is regulated to a certain value or less. It is set in a different form. In both cases of the second embodiment and the third embodiment described above, similar to the first embodiment, the conventional defect, that is, the strip-shaped base portion 23a of the surface fastener 23 at the time of mold opening is the concave groove 24a in the fastener support member 24. Opposite side walls 24b, 24 of
The inner surface of b is strongly rubbed, and as a result, the surface fastener 23 falls off from the foam molded body 20, or the surface fastener 2
It is possible to avoid the problem that a part of the foamed molded body 20 is peeled off together with 3, and the surface fastener 2 is provided at a predetermined position of the foamed molded body 20.
It is possible to manufacture a product (sheet cushion pad with hook and loop fastener) 3 that is firmly and surely integrally fixed as described above, with a good yield. In the above-described first to third embodiments, the surface fastener 23 is laterally drawn and the foamed molded product 2 is used.
Although the case where it is integrally fixed to 0 has been described, the same effect can be expected even when it is applied to the case where it is integrally fixed to the foam molded body 20 in the vertical pulling specification.

As described above, according to the present invention, the hook-and-loop fastener fixed to the surface of the foam-molded product along with the mold opening operation after foam-molding has an arcuate shape about a predetermined rotation center. It is possible to control the slip-out resistance when moving out of the concave groove of the fastener support member fixed to the lower mold to a certain value or less while moving while drawing a rotational trajectory, so the belt-shaped base of the surface fastener supports the fastener when opening the mold. The inner surface of the side wall of the groove facing the concave groove of the member is not strongly rubbed, and the occurrence of defective products such as the surface fastener falling off from the foam molded product or part of the foam molded product peeling off together with the surface fastener is reduced. As a result, a product (sheet cushion pad with hook-and-loop fasteners) can be manufactured with a good yield, in which the hook-and-loop fasteners are firmly and integrally fixed to the foam molding at predetermined positions. There is an effect that kill. In particular, when adopting the configuration as claimed in claim 3 or claim 4, since the surface fastener can be strongly elastically fitted and held in the concave groove of the fastener supporting member, the foamed resin in the molding die is formed. It is possible to reliably prevent the surface fastener from moving unexpectedly during material injection or foaming and hardening, or to prevent the surface fastener from rising due to the foamed resin material entering the concave groove, further increasing the non-defective rate. Yes, and claim 5 and claim 6
In the case of adopting the configuration described in (1), the structure of the fastener supporting member can be improved very simply, and since it is not necessary to adopt an inclined surface in the molding die itself, it is easy to reduce the cost of the molding die.

[Brief description of drawings]

FIG. 1 is an enlarged vertical cross-sectional view of a main part showing a first embodiment of a molding die used in a method of manufacturing a seat cushion pad with hook-and-loop fastener according to the present invention.

FIG. 2 is an enlarged vertical cross-sectional view of the essential parts showing a second embodiment of the molding die used in the method for manufacturing the seat cushion pad with hook-and-loop fastener according to the present invention.

FIG. 3 is an enlarged vertical cross-sectional view of the essential parts showing a third embodiment of the molding die used in the method for manufacturing a seat cushion pad with hook-and-loop fastener according to the present invention.

FIG. 4 is an overall vertical cross-sectional view showing a state in which a seat cushion pad with hook-and-loop fastener is being manufactured using a split mold.

FIG. 5 is an overall vertical cross-sectional view showing a state in which a seat cushion pad with hook-and-loop fastener is manufactured using a three-division type molding die.

FIG. 6 is a schematic perspective view for explaining an example of the form of a seat cushion pad with hook-and-loop fasteners formed by integrally fixing hook-and-loop fasteners to the surface of a foamed molded body that constitutes the seat cushion body.

FIG. 7 is an enlarged vertical cross-sectional view of a main part in FIGS. 4 and 5.

[Explanation of symbols]

10A, 10B Mold 11 Upper mold 12 Lower mold 12s reference plane Center of rotation of 14-face fastener 15 core type 20 foam molding 23-face fastener 23a band-shaped base 23b Engaging element 24 Fastener support member 24a concave groove 24b both side walls 24a1 Upper half inner surface R rotation locus

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) B29K 105: 20 B29K 105: 20 B29L 31:58 B29L 31:58 F term (reference) 3B100 DA04 DB00 DB08 4F202 AD07 AD24 AG20 AH26 CA01 CB01 CK25 CQ05 4F204 AD08 AD16 AG20 AH26 EA01 EB11 EF01 EF05 EF37 EK24 EK25 EK26

Claims (7)

[Claims] 1. A fastener supporting member having a groove-shaped cross section is fixed to a predetermined position of a lower die of a molding die, and a plurality of engaging elements are projected into one surface of a belt-shaped base in the groove of the fastener supporting member. The hook-and-loop fastener thus constructed is housed so that its engaging element abuts the bottom surface of the concave groove, and in this housed state, the foaming resin material is injected into the molding die for foam molding, and then the foam molding body is formed. The surface fastener that is integrally fixed is pulled out from the groove to open the mold so as to resist the resistance,
A method for manufacturing a seat cushion pad with surface fasteners, wherein the surface fasteners are integrally fixed to the surface of the foamed molded article, wherein the fastener support member is in a form in which the slip-out resistance can be regulated to a certain value or less. A method for manufacturing a seat cushion pad with a hook-and-loop fastener, wherein a hook-and-loop fastener is housed in a groove of the fastener support member in a set state. 2. As the molding die, an upper die and a lower die, or an upper die and a lower die to which a core die is attached, can be opened and closed by relative rotation around a fulcrum axis set on the outer peripheral portions of the both die. 2. The method for manufacturing a seat cushion pad with hook-and-loop fastener according to claim 1, wherein the upper die and the lower die are rotated relative to each other around a fulcrum axis, and the die is opened by using a forming die provided in. 3. A configuration in which the pull-out resistance can be regulated to a certain value or less so that both side walls facing each other across the groove are substantially along the rotational locus of rotation of both end edges of the strip-shaped base portion of the surface fastener at the time of mold opening. 3. The method for manufacturing a seat cushion pad with hook-and-loop fastener according to claim 1 or 2, wherein the fastener support member as a whole is inclined with respect to a reference surface of a lower mold in a molding die and fixed at a predetermined position of the lower mold. 4. The method for manufacturing a seat cushion pad with hook-and-loop fastener according to claim 3, wherein an inclination angle of the entire hook-and-loop fastener supporting member with respect to the reference surface of the lower die is about 20 °. 5. As a form in which the pull-out resistance can be regulated to a predetermined value or less, both side walls facing each other across the groove are fixed to a predetermined position of the lower mold in a state of being perpendicular to a reference surface of the molding mold. Of the above both side walls of the fastener support member,
At least the upper half inner surface of the side wall far from the center of rotation of the surface fastener at the time of mold opening is formed into a curved surface that substantially follows the rotation locus of both end edges of the belt-shaped base portion of the surface fastener. Alternatively, the method for manufacturing the seat cushion pad with hook-and-loop fastener according to item 2. 6. A structure in which the pull-out resistance can be regulated to a certain value or less, and both side walls facing each other across the concave groove are fixed to a predetermined position of the lower mold in a state of being perpendicular to a reference surface of the molding mold. 3. The surface according to claim 1, wherein the both side walls of the fastener support member are set to have a minimum height dimension within a range sufficient to elastically fit and hold the surface fastener housed in the groove. A method for manufacturing a seat cushion pad with fasteners. 7. The foam-molding method according to claim 1, wherein the fastener support member is arranged so that the hook-and-loop fastener is integrally fixed to the foam-molded article in a posture along the width direction of the foam-molded article. A method for manufacturing a seat cushion pad with hook and loop fastener according to any one of the above.