JP2003245926A - Method for manufacturing cushioning material comprising spring structural resin component and concrete-made female die used for its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method in which a release agent is not required, a molding time is shortened and a cost is reduced, in the method for manufacturing a cushioning material comprising a spring structural resin component which is recyclable, has high degree of freedom for a shape and size, is cheap, is reduced in sinkage, is hard to fatigue when it is used for a long time, is excellent in impact resistance, load resistance and the like, and is further suitable for a seat for an automobile, a motorcycle or the like, a saddle for horse riding, a chair, a sofa, a bed or the like on which a person sits, sleeps, steps or the like. <P>SOLUTION: The spring-structural resin component 30 comprising filaments 31 is placed on a cavity 12 of a concrete-made female die 11, is softened by hot water fed from a hot water feeding system 13 and is compression-molded by a base 4 constituting a male die 14 fixed on the tip end of a pantagraph jack 15. In the concrete-made female die 11, there is no fear such that the surface of the spring structural resin component 30 is burnt and a raw material resin does not adhere in mold release. <P>COPYRIGHT: (C)2003,JPO

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 made of a resin molded product having a spring structure, and more specifically,
It is excellent in impact resistance and load resistance, etc., and it is also possible to meet a large number of unspecified specific characteristics in each field, such as individual shape and size, and automobiles, motorcycles, bicycles, trains, aircraft, etc. A seat seat, a saddle for riding, a chair, a sofa or a bed, etc., a method of manufacturing a cushioning material made of a resin molded article having a spring structure that can be applied to anything on which a person sits, sleeps or rides, in particular,
The present invention relates to a method for manufacturing a cushion material made of a resin molded product having a spring structure using a female mold made of concrete. Further, the present invention relates to a concrete female mold used in the manufacturing method.

[0002]

2. Description of the Related Art At present, urethane foam is mainly used as a cushioning material for seats and beds of automobiles, motorcycles, bicycles, trains, airplanes and the like. Cushioning materials are generally used in some form where people sit, sleep, or ride, whether or not they are accompanied by vibration.In fact, urethane foam is used in all fields. It is widely used, and it is considered that there are few problems in terms of manufacturing method and cost, and the penetration rate is very high.

As such a cushion material, for example,
In Japanese Patent No. 2995325, the seat surface portion is made of high resilience foam having a single layer structure, and the high resilience foam is made of tolylene diisocyanate (TD).
There has been proposed a seat cushion pad for an automobile, which is made of urethane foam and contains I) in an amount of 10% by weight or less, with the balance being isocyanate having diphenylmethane diisocyanate. Also, Japanese Patent No. 2548
No. 477 proposes a cushion structure in which high melting point polyester fibers are fused with a low melting point thermoplastic elastomer. Also, Japanese Patent Laid-Open No. 2000-5101
No. 1 proposes a cushion in which synthetic fibers or natural fibers having a denier of 1 to 20 are partially bonded with a synthetic rubber adhesive or a crosslinkable urethane.

[0004]

Generally, when a person sits down, the load is concentrated on one place, so that the depression is large and the balance is unstable. There are issues such as fatigue. This is because the urethane foam is formed by uniformly foaming, so that the density and strength are constant, and it is difficult to change the strength and density for each part as necessary. Further, since urethane foam is too flexible, it has a great feeling of pushing up from the bottom, a feeling of bottoming, and a feeling of rocking, and when sitting for a long time, it may cause numbness of the legs and strong fatigue. For example, in the case of automobiles and motorcycles, the requirements are diversified due to the manufacturing method and structure of urethane foam, but the density of the material is constant, and the surface pressure distribution changes during actual use, so functionally, It may not be optimal. Since urethane foam is foam-molded, the spring characteristics are uniform or the types are rough, and it is difficult to change it as necessary. Therefore, it is difficult for urethane foam to meet various demands for spring characteristics. For example, in the case of a motorcycle, the spring characteristics must be changed according to the riding posture and condition such as for touring, road racing, motocross, etc., but the seats are not suitable for this. It is necessary to raise and lower the hips. As the body floats longer, the center of gravity rises and the balance becomes unstable.

Urethane foam also has problems in the manufacturing method. For example, the urethane foam molding die is made of metal such as FC, casting, aluminum, iron, etc., but not only the cost of the die itself is high, but also the metal has good heat dissipation, so the surface temperature easily rises, At the time of molding, since the raw material resin easily adheres to the mold, a mold release agent is required.
As described above, the urethane foam has a complicated molding process such as a mold releasing operation after foaming in the mold (for example, 3 minutes), and the molding time is long.

Further, since urethane foam is a thermosetting resin, it is difficult to recycle it. As a recycling method, what is made into chips by a pulverizer is adhesively molded into a material called chip foam (ribbon dead foam). It is only regenerated or burned and recovered as heat energy. Landfill treatment and incineration treatment can be mentioned as a disposal method, but the landfill treatment of urethane foam having a low bulk density and softness makes it difficult to stabilize the ground and limits the landfill location. It is also possible to process the material into powder or the like for landfilling, but this requires cost and labor. On the other hand, during combustion, there is a possibility that hydrocyanic acid gas (hydrogen cyanide) may be generated, so that the incinerator is greatly damaged and the hydrocyanic acid gas may be expensive to remove. In this way, due to the relationship with the Recycling Law, it is difficult to deal with environmental issues such as burial treatment.

In addition to the above, urethane foam has the following problems. Difficult to clean. This is because the amine catalyst used during production remains in the foam and gives off a bad odor. Further, since it has no air permeability and has heat storage property, it is apt to get stuffy and may start to burn if a concentrated light beam is continuously applied for a long time. Poor environmental performance. Although the expiry date of the CFC substitute used as a foaming agent in the production of urethane foam is 2020, the present situation is that there is no CFC substitute that is superior in foaming performance to the CFC substitute. In addition, TDI, which is an isocyanate usually used in the production of flexible urethane foam, has a concentration of 0.005 according to Ministry of Labor Notification No. 25.
It is a highly toxic substance that has been determined to be less than or equal to ppm, and if it is not thoroughly controlled at the actual manufacturing site, it may endanger the health of workers.

Regarding the characteristics of the flexible urethane foam among the above problems, the above-mentioned prior art patent No. 29953 is used.
Although improved in No. 25, other issues with urethane foam remain unresolved.
In addition, the cushion structure proposed in Japanese Patent No. 2548477 is difficult to recycle because the polyester fiber having a high melting point is fused with the thermoplastic elastomer having a low melting point, and the manufacturing method is complicated and the processing cost is extremely high. And other issues remain. In addition, JP-A-2000-51011
No. has good breathability and can be washed, but
It has problems such as poor durability, complicated manufacturing method, and extremely high processing cost. Furthermore, since the rubber-based adhesive and the crosslinkable urethane are thermosetting resins and not a single composition,
It is difficult to recycle.

As described above, even though it has various problems as described above, it is equivalent to or more than urethane foam as a cushioning material used for seats and beds of automobiles, motorcycles, bicycles, trains, aircrafts, etc. Currently, there is no alternative material that can be manufactured at low cost in addition to the above performance.

In view of the above, the present invention replaces urethane foam, which is difficult to recycle and has the above-mentioned problems in waste disposal, with seating seats for automobiles, motorcycles, bicycles, trains or airplanes, saddles and chairs for horse riding. An object of the present invention is to provide a manufacturing method suitable for a cushion material made of a resin molded product having a spring structure, which is suitable as a cushion material used for sitting, sleeping or riding on a person such as a sofa or a bed. Specifically, the molding process is easy,
It has a high degree of freedom in shape and size, is inexpensive, has little sinking, and evenly distributes pressure when sitting, so it does not fatigue even after long-term use. It is an object of the present invention to provide a manufacturing method capable of easily manufacturing a molded product having physical properties such as weight resistance strength and impact resistance. In particular, it is an object of the present invention to provide a manufacturing method that does not require a release agent, can shorten the molding time, and can reduce the cost of the mold.

[0011]

The invention according to claim 1 is
A predetermined pattern formed by contact-entangled assembly of adjacent linear filaments of continuous and / or hollow continuous filaments and / or short filaments of at least a thermoplastic resin on a concrete female mold Placing a three-dimensional structure having voids of bulk density, and heating the female mold and / or the three-dimensional structure under temperature conditions necessary for softening the three-dimensional structure,
A method for manufacturing a cushioning material comprising a spring-structured resin molded product, characterized in that the three-dimensional structure is clamped by the female mold and the male mold, and the three-dimensional structure is cured by cooling.

The "continuous filaments and / or short filaments" are preferably general-purpose plastics (polyolefin, polystyrene resin, methacrylic resin, polyvinyl chloride, etc.), engineering plastics (polyamide, polycarbonate, saturated polyester, polyacetal, etc.), etc. is there. For example, it is preferably made of a thermoplastic elastomer such as polyethylene (hereinafter referred to as PE), polypropylene (hereinafter referred to as PP) or nylon.

Particularly, a polyolefin resin such as PE or PP is mixed with vinyl acetate resin (hereinafter referred to as VAC), vinyl acetate vinyl copolymer (hereinafter referred to as EVA) or styrene butadiene styrene (hereinafter referred to as SBS). Those are preferable. At this time, the mixing ratio of the vinyl acetate content of the polyolefin resin and VAC or EVA is 70 to 97% by weight:
3 to 30% by weight, preferably 80 to 90% by weight: 10
20% by weight is preferred. This is 3 VAC or EVA
This is because the impact resilience is reduced when the content is less than 30% by weight and the thermal characteristics are reduced when the content is more than 30% by weight. The mixing ratio of the polyolefin resin and SBS is 50 to 97% by weight: 3 to 50% by weight, preferably 70 to 90% by weight.
0 to 30% by weight is preferable. Further, the polyolefin resin may be a recycled resin.

The structure of the "continuous line and / or short line" may be solid or hollow. In the case of a hollow continuous line and / or a short line, air is trapped in the tube, the characteristics of the air spring are developed, and a unique cushioning property is generated, which is preferable. Buckling can also be prevented. Moreover, the rigidity of the three-dimensional structure is maintained by the entry of air. The hollow may be continuous or discontinuous. An example is a case in which one filament has both a hollow portion and a portion in which the hollow portion is closed. The mixing ratio of solid filaments and hollow filaments is solid: hollow = 0 to 50:50 to 1.
It is preferably 00. At this time, it is preferable to use a hollow filament in the central portion and to cover the outer periphery of the hollow filament with a solid filament so that the tactile feel is good.

The diameter of the "continuous wire and / or short wire" is
In the case of a solid filament, 0.3 to 3.0 mm, especially 0.
It is preferably 7 to 1.0 mm. In the case of a solid linear shape, when the wire diameter is 0.3 mm or less, the filament becomes stiff, the number of fused portions increases, and the porosity decreases. 3.0 mm
In the above, the filaments are too stiff, loops or curls are not formed, the number of fused portions is reduced, and the strength is reduced. Moreover, in the case of a hollow filament, it is preferably 1.0 to 3.0 mm, and particularly preferably 1.5 to 2.0 mm. Hollow rate is 1
When it is 0% or less, it does not contribute to weight reduction, and when it is 80% or more, the cushioning property is deteriorated.

The bulk density of the "spring structure resin molded product" is 0.005 to 0.08 g / cm ³ , preferably
It is preferably 0.02 to 0.06 g / cm ³ .
When the bulk density is 0.005 g / cm ³ or less, the strength decreases. When the bulk density is 0.08 g / cm ³ or more, the weight cannot be reduced and the elasticity disappears. Further, the resin molded product having the spring structure is not limited to have a constant density as a whole, and may have a dense structure at predetermined intervals. In this case, the bulk density is 0.005 to 0.03 g / cm ³ , preferably 0.008 to 0.03 g / cm ³ , and particularly 0.01 to 0.01 in the rough portion.
0.03 g / cm ³ is preferred. 0.0 in the dense part
^{3 to} 0.08 g / cm ³ , preferably 0.04 to 0.0
7 g / cm ^3, in particular 0.05~0.06g / cm ³ preferred.

The "spring structure resin molded product" has a porosity of 96 to 99%, preferably 97 to 99%, and particularly 9%.
It is preferably 7 to 98%. The porosity is preferably in the above range in order to maintain the elasticity and strength of the cushion and reduce the weight. [Porosity (%)] = (1- [bulk density] / [density of resin]) × 100

The "cushion material" is preferably composed of a multi-layer resin molded product having a spring structure. Further, the use of the cushion material is preferably an automobile, a motorcycle, a bicycle, a seat of a train or an aircraft, a saddle for riding, a chair, a sofa or a bed. In addition to the above examples, as a substitute for urethane foam that is used as a cushioning material for people to sit, sleep, or ride, regardless of where vibration is involved or not,
Widely available.

Here, it is simpler than the secondary processing of urethane foam, and can meet more detailed needs than urethane foam. Also, since it is compression molding, the added value of the product is increased by molding an original one according to the body shape of the individual, and it is possible to respond to custom-made products, etc. It is easy to manufacture a flexible cushioning material. Further, the spring characteristics can be made variable by changing the diameter, material, denier, bulk density, porosity, etc. of the wire of the spring structure resin molded product. That is, although the spring characteristic as a material is constant, it is possible to draw by compression molding, so that the cushion function can be changed and the load distribution can be made variable. Further, the thickness of the cushion material can be made variable by adjusting the stroke.

Particularly, by using a female mold made of concrete, PE and P constituting a resin molded product having a spring structure are formed.
Since the raw material resin such as P does not adhere to the mold, the mold release agent which is indispensable in the molding method using the metal mold becomes unnecessary. In addition, the temperature of concrete is more uniform than that of metal, and there is no risk of the surface of the spring structure resin molded product being burnt. Further, since the molding process is simplified and the molding time is shortened, it is possible to mass-produce the cushion material. At this time, it is preferable to use a product (base) to which the cushion material is attached as the male mold. As a result, it is not necessary to separately prepare a male mold, which reduces costs and improves molding accuracy. The cooling may be natural cooling or forced cooling. Water is preferably used for the forced cooling.

According to a second aspect of the present invention, continuous and / or hollow continuous filaments and / or short filament random loops or curls consisting of at least a thermoplastic resin are contact-entangled with each other to form adjacent loops. A female mold made of concrete used for molding a spring-structured resin molded product composed of a three-dimensional structure having voids of a predetermined bulk density, which is molded according to the original shape of the spring-structured resin molded product. A female mold made of concrete characterized in that concrete is poured into a mold and cured.

Since concrete has excellent formability and can be produced by simply kneading it and pouring it into a mold, the cost of the mold itself is reduced (for example, 1/50 to 1/100) and a mold having a complicated shape is produced. It is also possible to duplicate the same thing easily. For example, the same dimensions can be measured when manufacturing the mold, and even the pattern of the mold can be taken,
Easy to get used to the product. Thereby, the concrete female mold used in the method for manufacturing a cushion material according to the first aspect can be suitably obtained.

[0023]

BEST MODE FOR CARRYING OUT THE INVENTION As shown in the perspective view of FIG. 1, the front view of FIG. 2A and the rear view of FIG.
Is a spring structure resin molded product 30 which is a three-dimensional structure molded from a mixture (for example, a thermoplastic elastomer) of a thermoplastic resin, for example, a polyolefin resin such as PE or PP and VAC, EVA or SBS. Is manufactured by compression molding as described below.

(Explanation of Spring Structure Resin Molded Product 30)
First, the spring structure resin molded product 30 will be described. Spring structure resin molded product 3 used in this embodiment
0 is a three-dimensional structure having voids formed by randomly intertwining aggregates of continuous filaments and / or short filaments (hereinafter, simply referred to as filaments 31) using the above mixture as a raw material.
Form a plurality of loops or curls (see a partially enlarged view A of FIG. 1). In the present embodiment, the spring structure resin molded product 30 is composed of a hollow wire 31 as shown by the cut surface 31a (see a partially enlarged view B of FIG. 1).

Here, the bulk density of this three-dimensional structure is
0.005-0.03 g / cm ³ , preferably 0.0
08-0.03 g / cm ³ , especially 0.01-0.03 g
/ Cm ³ is preferable. The porosity of this three-dimensional structure is 96 to 99%, preferably 97 to 99%.
%, Particularly preferably 97 to 98%.

(Description of Cushion Material 1) Next, the cushion material 1 will be described. The cushion material 1 is manufactured by compression molding the spring structure resin molded product 30. The cushion material 1 in the present embodiment is shown in FIG.
As shown in the side view of FIG. 1, it is a cushioning material mainly used for a seat of a motorcycle (for example, a motorcycle 10).

The cushion material 1 is provided with a two-layer seat (upper seat 2 and lower seat 3) having the same or different spring characteristics and is fixed to the base 4. At this time, it is preferable that the upper sheet 2 and the lower sheet 3 are bonded to each other with an adhesive or a double-sided tape. The spring characteristics can be varied for each sheet or portion depending on the density, material and / or wire diameter of the spring structure resin molded product 30. Specifically, it is preferable to change the spring characteristics such that the lower layer is hard and the upper layer is soft.

For example, in this embodiment, the upper sheet 2 has a lower rigidity and a lower flexibility than the lower sheet 3. This is because the buttocks and the like directly touch the upper sheet 2 with respect to the lower sheet 3 fixed to the base 4. At this time, it is preferable to appropriately form a raised portion on the upper seat 2 so that the upper seat 2 can be fitted to a posture in which a person rides. On the other hand, since the lower sheet 3 is fixed to the base 4, it needs to be harder than the upper sheet 2. At this time,
It is also preferable to have a structure in which the overall shape of the cushion material 1 is maintained by the hardness of the lower sheet 3.

Further, the cushion material 1 is provided by the lower sheet 3.
Exhibits unique suspension characteristics. For example, a conventional seat that uses urethane foam has a large road surface reaction force (kickback) that is unsprung vibration, and therefore a close contact coil spring is often inserted in urethane to receive the road surface reaction force. However, in the present embodiment, the two-layer structure is used in this manner, and the load of a person can be received by the flexible upper sheet 2, and the stiff lower sheet 3 can also receive the unsprung vibration. This eliminates the need for a close contact coil spring. Therefore, it is advantageous in terms of weight and structure, is simple, and does not require a special part structure. Since the volume is reduced, the moment of gravity is lowered, which contributes to the stability of the posture. Further, the thickness of the cushion material 1 can be freely adjusted by adjusting the stroke of the male mold at the time of compression molding so that it can be applied to various suspensions having different shapes or sizes.

Further, since the cushion material 1 is made of the spring structure resin molded product 30, the air permeability is excellent. Therefore, needless to say, the cushioning material 10 does not get damp.
If air for cooling and heating is ventilated from the cooling and heating duct inside,
The seat of the motorcycle 10 can be provided with an air conditioning function. Further, if it is used as a seat for automobiles, it can be used for high-end vehicle specifications without using special materials.

The cushion material 1 including the upper sheet 2 and the lower sheet 3 is needless to say not limited to the illustrated shape, but can be formed in an appropriate shape. For example, the layers of the sheets may be one layer without overlapping the sheets. When stacking the sheets, two or more layers may be used. Further, of the two or more sheets, for example, the lower layer sheet may be made of synthetic rubber or the like, but at least one sheet (preferably the upper layer) is preferably made of the thermoplastic resin. Further, the shape and the like of the raised portion are not limited to those in this embodiment. In particular, it is possible to meet product requirements, characteristics and unspecified numerous small needs in each field such as individual shapes and sizes.

Further, a cushion material having a multilayer structure (for example,
It is also preferable that a cushion material made of a resin molded product having a spring structure that is sewn (hand-sewn or machine-stitched) is superposed on the upper sheet 2) of the cushion material 1 to form the uppermost sheet (not shown). In this case, in particular, it is possible to express even complex irregularities and subtle changes that are difficult with conventional molding, and to meet product requirements, characteristics and unspecified numerous small needs in each field such as individual shape and size. It will be more rigorous and can be custom made depending on the car model and body type. For example, when using it as a seat for a motorcycle 10 or an automobile, a driver who is particular about the driving posture (for example, a person who uses it as a profession)
It is possible to provide a seat that can meet the requirements such as the above and that fits precisely to the driving posture and driving motion of each person. In addition, the added value of the product can be increased.

The upper sheet 2 and the lower sheet 3 are formed into a shape corresponding to the base 4. As shown in the perspective views of FIGS. 4 (a) and 4 (b), the base 4 is a base portion that constitutes a seat of the motorcycle 10, and a stop portion 4a is formed in the front and a raised portion 4b is formed in the rear central portion. A metal fitting 4c for attaching to the frame of the motorcycle 10 is fixed to the back side of the raised portion 4b. Also, on the back side of the base 4,
A cushion 4d made of rubber or the like is fixed at several places (for example, 6 places). In addition, grooves and holes as shown are formed.

(Manufacturing Apparatus and Manufacturing Method of Cushion Material 1) Next, the manufacturing apparatus and manufacturing method of the cushion material 1 of the present embodiment will be described with reference to FIGS.
A method for manufacturing the spring structure resin molded product 30 will be described later.

(1) Loading Step FIG. 5 is a side sectional view for explaining the first step of the compression molding step for the cushion material 1, and FIG. 6 is a front sectional view for explaining the first step. As shown in the explanatory view of FIG. 5 or FIG. 6, one or more spring-structured resin molded products 30 are placed on the cavity 12 of the concrete female mold 11 (hereinafter simply female mold 11). At this time, two or more spring structure resin molded products 30 having the same or different spring characteristics may be placed at the same time.
As described above, the spring structure resin molded product 30 is a three-dimensional structure having voids formed by randomly intertwining filaments 31. The filaments 31 form a plurality of loops or curls ( (See a partially enlarged view C of FIG. 5).

In the present manufacturing method, since it is necessary to have a temperature equal to or higher than the softening point of the raw material resin forming the filament 31 of the spring structure resin molded product 30, the cavity 12 of the female mold 11 is required.
Hot water (preferably 70 ° C. or higher) is poured from the water heater 13 to the spring structure resin molded product
To soften. The hot water used here is the female mold 1.
This is for heating the spring structure resin molded product 30 from inside 1. Further, the female mold 11 itself may be heated by a heater or the like. At this time, it is preferable that a heat conductor (for example, a heater) is embedded in the concrete of the female mold 11.
It is also preferable to cover the periphery of the female mold 11 with a heat insulating material in order to enhance the heat retaining effect (for example, a container of wood, foamed resin, or the like). In addition, the wire strip 31 that constitutes the spring structure resin molded product 30
When it is necessary to heat the ambient air (including the air in the hollow portion in the case of a hollow filament), it is also preferable to mold with the heat retention residual heat of the female die 11. Further, instead of the hot water supply device 13, the steam may be heated by the steam supply device 17 or the like. When steam is used, for example, a steam injection hole is formed in the female mold 11, and steam is injected into the cavity 12 through the steam injection hole. It is preferable to inject steam and heat at the mold clamping stage. This is preferable because the heat becomes uniform and the molding can be performed at a higher temperature. In addition, there are molded products that require not only heating but also pressure. In this case, heating and pressing with steam can be performed. Since some shapes cannot be heated mechanically, it is possible to handle complicated shapes by using atmospheric pressure.

The female mold 11 is made by molding a product mold with an appropriate material such as gypsum, and inverting the mold.
It is manufactured by fixing the plate horizontally below, applying a mold release agent to the mold and plate appropriately, kneading concrete powder with water, dropping it into the mold to solidify, and releasing from the mold. .
After the concrete is hardened, the female mold 11 is completed by turning it upside down and removing the form and plate. At this time, the strength, rigidity and thickness of the concrete can be adjusted by forming a space under the plate on which the formwork is placed, and moving the plate up and down to adjust the space. For example, when increasing the thickness of concrete, the plate fixing position is lowered. Further, surface polishing is appropriately performed. In this way, concrete is excellent in moldability and can be produced by simply kneading it and pouring it into a mold, so that the cost of the female mold 11 itself is reduced (for example, 1/50 to 1/100 of that of a conventional mold). Also, the female mold 11 having a complicated shape can be manufactured, and the same product can be easily duplicated, so that the accuracy is improved. For example, the same dimensions can be measured when the female die 11 is manufactured. Further, since concrete is easily adapted to the product, it is possible to form the cushion material 1 smoothly by polishing the surface, just by clamping the mold. Further, the pattern of the mold can be taken, and for example, by applying vinyl and clamping the mold, it is possible to perform surface processing such as applying a pattern to the surface based on the degree of surface roughness of vinyl.
In addition, since the female mold 11 is made of concrete, it is possible to suitably withstand the pressure applied during the molding of the cushion material 1, and since it has high durability, it can be used tens of thousands of times. The weight of the female mold 11 is preferably 50 to 100 kg.

The male mold 14 is composed of a base 4 and a male mold base 14a. The male mold 14 is fixed to the tip of the pantograph jack 15 at a plurality of positions by fixing tools, and the pantograph jack 15 clamps the spring structure resin molded product 30 on the cavity 12 of the female mold 11 from above. The male mold 14 is preferably capable of withstanding a pressure of 10 tons or more. In the present embodiment, for one male mold 14,
By installing a plurality (for example, three) pantograph jacks 15, the load pressure is improved and the load is distributed at a plurality of locations (for example, three locations). The pantograph jack 15 may be manually operated, but may be automatically operated by appropriately attaching the motor 15a. The upper end of the pantograph jack 15 is fixed to the upper base 18, and the upper base 18 is fixed to the upper part of the female mold 11 by the support column 19. By using the pantograph jack 15, the equipment can be simplified and the cost can be reduced. However, instead of the pantograph jack 15, a hydraulic cylinder, a pneumatic cylinder or the like may be used.

As the male mold 14, it is preferable to use the base 4 which is a part of the product. The base 4 is attached such that the rear surface is fitted to the lower surface of the male base 14a. The upper surface of the male base 14a is fixed to the pantograph jack 15 by a fixing tool. In this way, since a part of the product (base 4) constitutes a part of the manufacturing apparatus (male mold 14), only the female mold 11 needs to be prepared, and the male mold 1
No need to manufacture 4 separately. Conventionally, it has been necessary to manufacture a male mold and a female mold for a urethane foam molding separately from the product, but in this manufacturing method, since the male mold 14 itself is a part of the product, a stand, a punch, etc. Is unnecessary, cost can be reduced, and molding accuracy is improved.

(2) Clamping Step FIG. 7 is a side sectional view for explaining the second step of the compression molding step for the cushion material 1, and FIG. 8 is a front sectional view for explaining the second step. As shown in the explanatory view of FIG. 7 or FIG.
(Also used as)) as shown by the arrow in the figure, and clamp the mold. Here, the cavity 12 of the female mold 11 is set to a size for deep drawing, and the stroke can be made deep or shallow. That is, since the mold has a margin, the thickness of the cushion material 1 can be varied by adjusting the stroke of the diaphragm. Therefore, the thickness of one mold can be varied. Also, naturally, the density is also variable. In this way, by making the stroke of the male die 14 variable, it is possible to manufacture with one type of die, deep drawing and shallow drawing, and it is possible to freely change the density, spring characteristics, and rigidity.

As an effect of changing the stroke, the thickness of the cushion material 1 can be adjusted to be thin or thick. When making a thin cushion material 1, it is sufficient to make the stroke deep with the same mold, and when making a thick cushion material 1,
All you have to do is make the stroke shallower with the same model. That is, the thickness of the cushion material 1 can be controlled. Also, the density, spring characteristics, and rigidity can be controlled. As shown in the drawing, if the inclination angle (taper) of the side surface of the female die 11 is reduced (it is almost vertical in the figure), it is easy to adjust the thickness of the cushion material 1 with one die. For example, the tilt angle is 1/5
0 to 1/400 (for example, 1/200) can be mentioned. The inclination may be either inward or outward with respect to the vertical downward direction. If it leans inward too much, it may be difficult to control the stroke. As a result, one mold can meet the required product characteristics of various cushion materials 1. In particular, even with the same product, the thickness of the cushion material 1 can be arbitrarily selected. For example, it is possible to easily meet a large number of unspecified small needs, such as being made to order. In addition, in the part where the inner side of the thigh is in contact, the compression ratio may be increased and the spring characteristics may be hardened.
This has advantages such as improved cushioning properties and durability.

In general, the outer shape is almost the same because it is the width on which a person rides, but the thickness of the cushion material 1 is different depending on the model (suspension characteristics), so the thickness of the cushion material 1 is controlled according to each model. Required to do. However, in the case of urethane foam, since it is foamed and molded, only a uniform magnification can be realized. In addition, depending on the degree of aperture such as shallow aperture and deep aperture,
It is necessary to prepare many molds. According to the present manufacturing method, the above problems of urethane foam can be suitably solved.

(3) Trimming Process FIG. 9 is a plan view for explaining the third stage of the compression molding process of the cushion material 1. As shown in the explanatory view of FIG. 9, after the mold clamping state is maintained for a predetermined time, the male cutter 14 is moved by the heat cutter 16.
The burr 32 protruding from the end of the male mold 14 following the periphery of
At the same time as trimming (see a partially enlarged view D of FIG. 9), the ends are heat-welded. In the past, after molding, the dimensions were taken anew and trimming etc. was performed to adjust the shape,
The terminal trimming process was difficult. With this method, trimming can be easily performed. In particular, trimming at this stage eliminates the unraveling of the terminal, and it is not necessary to dimension the terminal later, and the processing is simple.

(4) Mold release step Cooling water is poured into the cavity 12 of the female mold 11 to solidify the spring structure resin molded product 30. The molding time can be shortened by adding water and quenching instead of gradually cooling. Then, after the curing time has elapsed, the mold is released. The pantograph jack 1 is used as a factor for determining whether or not it is solidified.
If 5 is loosened and there is no springback, it is in a solid state. Hereinafter, heating / cooling of the female mold 11 and / or the resin molded product 30 having the spring structure is repeated. In the case of a hollow wire, springback can be prevented by satisfying an appropriate thermal equilibrium condition considering the air in the hollow portion.

At this time, since the female mold 11 is made of concrete, the raw material resin does not melt to adhere to the female mold 11, and the mold release agent which is essential in the molding method using the metal mold is unnecessary. Become. In addition, the temperature of the concrete tends to be more uniform than that of the metal, and the spring structure resin molded product 30
There is no risk of burning the surface of. Therefore, in the female mold 11 made of concrete used in this embodiment, the molding process is simplified and the molding time is shortened, so that the cushion material 1 can be mass-produced.

(5) Final step As shown in the attachment explanatory view of FIG. 10, the upper sheet 2 and the lower sheet 3 obtained through the above steps are placed on the base 4 in a stacked manner and fixed. A heat-molded vinyl leather 5 is put on it, and the base 4 is fixed with a stapler or the like. You may adhere with double-sided tape. Also, in the molding process, the lower sheet 2
By forming convex portions (or concave portions) on the base 4 and fitting and fixing the concave portions (or convex portions) appropriately provided on the base 4, a stapler or a double-sided tape becomes unnecessary. Further, the upper sheet 2 and the lower sheet 3 can be appropriately adhered to each other with an adhesive or a double-sided tape to prevent them from being displaced. Similar to the above, the upper sheet 2 and the lower sheet 3 may be provided with irregularities so that the upper sheet 2 and the lower sheet 3 are fitted and fixed. However, in the case of covering with vinyl leather 5 etc. in this process,
In some cases, the upper sheet 2, the lower sheet 3, and the base 4 do not have to be fixed.

(Method for Manufacturing Spring-Structure Resin Molded Product 30) Next, an example of a method for manufacturing the spring-structure resin molded product 30 will be described. As shown in the schematic view of FIG. 11, a spring structure resin molded product 30 according to the present embodiment.
In the production method of, preferably, a polyolefin resin such as PE or PP and a raw material resin such as VAC, EVA or SBS are dry blended through a tumbler, a cutting feeder, a constant amount feeder, or the like described later, or Extruder 2 after being mixed or melt mixed and pelletized
0 is sent to the hopper 21.

Specifically, raw resin such as PP and S
BS with a tumbler (KR mixing machine manufactured by Kato Riki Seisakusho),
Mix for 15 minutes at 40 rpm.

Next, as shown in the perspective view of FIG. 12, the mixture of the raw material resins is charged from the hopper 21 of the φ65 m single-screw extruder 20 at a predetermined temperature (for example, 200 ° C. or higher).
Melt kneading at 260 ° C.), melt extruding from a large number of nozzles of a predetermined diameter provided in the molding die 22 at a predetermined extrusion speed, and taking out by a take-up machine 23 described later to obtain a predetermined wire diameter (for example, 600 to 90). 000 denier, preferably 3,000 to 30,000 denier, and more preferably 6,000 to 10,000 denier) to form solid and / or hollow filaments 31, which are in the molten state.
1, for example, 1 to 10 mm in diameter, preferably 1 to 1 in diameter
A 5 mm loop is formed, and the line 31 and the bus 2 are adjacent to each other.
A random loop is formed by contact entanglement within 5 (in water). At this time, it is preferable that at least some of the contact entangled portions are melt-bonded to each other. At this time, the filaments 31 may be hollow and solid filaments mixed in a predetermined ratio.

The thickness and bulk density of the three-dimensional structure, which is a set of random loops, are set between the take-up rolls 24, 24 of the take-up machine 23 in the bath 25. This three-dimensional structure (for example, thickness 10 to 200 mm, width 2,000 m
In m), the filaments 31 are randomly formed in a curl or loop shape, solidified in water, and taken out by the winding rolls 26, 26 as a spring structure resin molded product 30.

Further, when the filament 31 having the loop formed in water is pulled by the pulling machine 23, the cushion characteristic may be changed by changing the speed of the pulling machine 23. In that case, when relatively increasing the bulk density of this three-dimensional structure, 0.03 to 0.08 g / cm ³ , preferably 0.04 to 0.07 g / cm ³ , particularly 0.05.
It is preferable to set it to 0.06 g / cm ³ . Moreover, when reducing the porosity of this three-dimensional structure, 91-97
%, Preferably 92 to 96%, particularly preferably 93 to 94%.

Further, for example, the take-up rolls 24, 24
By adjusting the take-up speed of the take-up machine 23 to a low speed at a predetermined interval (for example, 3 to 5 m), for example, the take-up speed of the take-up machine 23 is set to a low speed within a set time by a timer or the like. In the longitudinal direction of 30, a portion having a large bulk density formed at low speed pulling and a portion other than that, that is, coarse and fine may be continuously formed at predetermined intervals (for example, 30 to 50 cm).

Further, as shown in the front view of FIG. 13, when it is difficult to bend the spring-structured resin molded product 30 which is a three-dimensional structure by the take-up rolls 24, 24 at the time of take-up, the rough bulk density portion is removed. By making it, it can be bent at that part and pulled up from the water.
The spring structure resin molded product 30 taken out through the above steps is cut by a cutting device 27 to an appropriate length.
The bath 25 is provided with a water supply valve and a drain valve (not shown).

As another example, as shown in the front view of FIG. 14, in the case where the cutting device 127 is provided in the bus 125, the cutting device 127 is arranged near the lower part of the take-up machine 123,
On the opposite side wall of the bus 125, there is provided a transfer device 128 including a conveyor having a plurality of locking protrusions that are inserted into a single space cut at the cutting site. For the configuration of the other parts, the above description is cited as the 100s.

By the manufacturing method described above, as an example, a spring structure resin molded product 30 having a bulk density of 0.03 g / cm ³ and a thickness of 50 mm was obtained. The three-dimensional structure can also be manufactured by using one or a plurality of combinations of different characteristics. In addition, for other details such as a manufacturing example and experimental results of the spring structure resin molded product 30 molded by the above manufacturing method, refer to Japanese Patent Application No. 2000-246907 previously developed by the present inventor.

(Other Embodiments of Spring Structure Resin Molded Product 30) Next, other examples than the spring structure resin molded product 30 of the above embodiment will be described. Various molding methods that utilize the viscoelastic behavior of the raw material resin are utilized.

In the manufacturing process of the resin molded article 30 having the spring structure, depending on the take-up speed and heat control,
It is possible to arbitrarily form a three-dimensional structure having different cushioning characteristics for each part. For example, like the spring-structured resin molded product 130 shown in FIG. 15A, the cushion characteristic can be gradually softened from the outer periphery toward the center in a predetermined range or gradually. Here, a hard portion 130 is formed on the outer circumference.
A soft portion 130b is formed at a and the central portion.
In addition, the spring structure resin molded product 2 shown in FIG.
It is also possible to make the cushion characteristic of the central portion hard, as in 30. Here, a hard portion 230a is formed at the center and a soft portion 230b is formed at the outer periphery. Also, FIG.
As in the spring structure resin molded product 330 shown in FIG. 5C, the cushion characteristic can be partially changed. Here, the hard portion 330a is partially formed in the soft portion 330b (for example, two places).

For example, a resin molded product 130 having a spring structure
If so, it is preferable as a cushion material for a seat of the motorcycle 10. By making the side surface of the cushion material 1 hard, when the vehicle is driven by sandwiching the seat, the cushion material 1 is suitably fitted to the inner thighs of the driver and the running stability is improved. Also, if the spring structure resin molded product 230,
It is also suitable as a cushion material for helmets. As described above, a hat (shade hat, helmet, etc.) whose hairstyle is hard to be collapsed can be manufactured by molding the surface (portion in contact with the head) of one three-dimensional structure with softness and the inside with hardness. This is preferable because it enables to shade and has good air permeability.

Depending on the load and the amount of bending, some cushion materials may be sufficient if only the surface is hard. In such a case, in addition to partially changing the density with a single three-dimensional structure as described above, a plurality of thin three-dimensional structures with different densities are manufactured, and by stacking them in various ways, A spring structure resin molded product can also be formed. According to this method, the amount of the raw material resin used can be reduced, and it is preferable in terms of productivity. For example, like a spring structure resin molded product 430 shown in FIG. 16A, a three-dimensional structure 430b having a low bulk density is stacked below the three-dimensional structure 430a, and a three-dimensional structure 430c having a further low bulk density is stacked below the three-dimensional structure 430b. Then, one spring-structured resin molded product 430 can be formed by bonding them together.

Further, as in the spring structure resin molded product 530 shown in FIG. 16 (b), the holes 5 are formed by partially melting with heat.
Partial reinforcement can also be achieved by forming 30a (partition block molding). The holes 530 may be formed before the compression molding, or may be formed after the compression molding. In addition, as shown in FIG.
A stopper 530b such as a metal fitting can be inserted into 30a. The stopper 530b may be inserted before the compression molding or may be inserted after the compression molding.

The wire diameters of the wire rods 31 forming the spring structure resin molded product 30 do not necessarily have to be equal. 1
Even with three cushion materials, the way the load is applied differs depending on the location. In order to partially harden that range, in addition to changing the bulk density, it is also possible to change the thickness and hardness of the filament 31 itself that constitutes the spring structure resin molded product 30. For example, it is preferable to use a thick line or a line having a high resin hardness at a location where the load applied to the buttocks is concentrated.

At this time, in order to partially manufacture the thick filaments, as shown in FIG. 17A, the molding die 622 is used.
It is preferable that the diameter of the nozzle opening 622a is partially (for example, central portion) larger than that of the normal nozzle opening 622b. As shown in FIG. 17B, this molding die 622
In that case, the thick filament 631 is extruded partially (for example, from the central portion) at the same time as the ordinary filament 31 to be extruded. This allows the rigidity to be changed in a complex manner.

Further, by changing the material of the filament 31, it is possible to mold a soft or hard cushion material having the same thickness and bulk density. For example, motorcycle 10
With the seat cushion material 1, various materials can be selected according to the weight of the occupant, and added value can be added to the product.

Further, the spring structure resin molded product 30 can be mixed and molded by entwining various things such as fibers and wires. As a result, it is possible to reinforce the weak points of the resin, which are weak against heat, weak against buckling, weak against pulling, and the like, which are entangled therein. For example, FIG.
It is preferable that a plurality of wires 733 are entwined with the filament 731, as in the spring structure resin molded product 730 shown in FIG. In addition, as shown in the cross-sectional views of FIGS. 18B and 18C, the wire 733 and the like are not only entangled with the filament 731,
It is also preferable to pass the hollow portion of the filament 731.

(Other Embodiment of Cushion Material 1) Female Mold 1
By changing the heating temperature stepwise when the spring structure resin molded product 30 is clamped by the 1 and the male mold 14,
It is also possible to use heat range molding in which the rigidity is partially changed. For example, like the cushion material 101 shown in FIG. 19A, a hard portion 101a (plate-shaped portion) can be formed below and a soft portion 101b can be formed above. At this time, it is preferable to heat the edge portion 101c to form a hard plate. For example, it is preferable to form the curled edge portion 101c into a plate shape during trimming. This edge portion 101c can be suitably fitted into the base 4. It is preferable that the edge portion 101c is once expanded and then hooked to the base 4 and then restored by elastic force so that the edge portion 101c is fitted and attached. With such a structure, the cushion material 101 and the base 4 can be attached and detached without engaging with a stapler or the like.

When the spring structure resin molded product 30 is clamped by the female die 11 and the male die 14, the female die 11 is hot-burned to raise the temperature of the die and weld the surface portion to harden it. It may be epidermis (skin) molding. As with the cushion material 201 shown in FIG. 19B,
Only the surface of the spring structure resin molded product 30 is melted and the skin 2
Since 01a can be formed, it is not necessary to coat (for example, cover with vinyl leather 5 or the like) by post-processing. For example, it can be used for molding a resin of an instrument panel. That is, the surface of the spring-structured resin molded product 30 may be melted in the mold to form a grain, and at the same time, integrally molded. In addition, when the cushioning material 1 needs to be prevented from unraveling, is waterproof, or when the material is preferably protected, it is particularly preferable to form the skin 201a by hot burning.

Since the cushion material 1 made of the spring structure resin molded product 30 in the present embodiment has air permeability, it may be better not to cover the vinyl leather 5 and the like in the subsequent step. In this case, FIG.
Like the cushion material 301 shown in (a) and (b), it is preferable to cover the periphery of the spring structure resin molded product 30 with a net 306 and perform compression molding. Further, the net 306 may be put on the cushion material 301 after compression molding. The net 306 is preferably made of a water-repellent material (for example, plastic). As a result, the air permeability is appropriately ensured, which is particularly effective in areas and seasons with high humidity. It is also suitable as a seat for cars that run on sand such as buggies. In addition, the net 306 is the cushion material 30.
It is also excellent in durability because it prevents unraveling of No. 1 and preferably protects it. The density of the meshes of the net 306 is not limited to that shown in the figure, and may be appropriate. In addition, the vinyl leather 5 may be put on after the net 306 is put on. This is to prevent foreign matter from entering due to mischief or the like in a seat such as a vehicle on which an unspecified large number of people ride.

(Other Embodiments of Mold) The upper and lower positions of the female mold 11 and the male mold 14 may be reversed. With this structure, the weight of the female mold 11 made of concrete is used as a weight instead of the weight, and compression molding can be performed using the weight. Further, as shown in FIGS. 21 and 22, it is also preferable that both the female mold 11 and the male mold 14 are made of concrete. At this time,
If the heavier one is used as the upper die (pressurizing side), compression molding can be performed by utilizing the weight of the upper die. For example, the upper mold may be heavy concrete, the lower mold may be lightweight concrete, the upper mold may be large, and the lower mold may be small.

In this embodiment, the pantograph jack 15 is used to quickly and evenly clamp the mold.
When the mold is clamped by its own weight using gravity, the pantograph jack 15 may be unnecessary. For example, as shown in the explanatory view of FIG. 21, the male mold 114 is suspended by a balancer 115 made of a spring material or the like, and as shown by an arrow in the drawing, the male mold 114 is molded with the female mold 111 by utilizing its own weight. Can be tightened. Further, as shown in FIG. 22, the female mold 211 and the male mold 214 are joined by a hinge 215,
It is possible to open the male mold 214 to a predetermined angle, move the male mold 214 as indicated by an arrow in the drawing, and use the own weight of the male mold 214 to clamp the female mold 211.

Air temperature conditions and temperature control are also important for molding requirements. Although the raw material resin is softened at the time of molding, it is not a bond at the molecular level and is not completely melted. Therefore, the air inside the spring structure resin molded product 30 is kept as it is. At this time, the air temperature and the softening temperature of the raw material resin must be in equilibrium. Therefore,
Even if the temperature is raised rapidly, if the mold is not clamped until the temperature of the internal air becomes uniform, the air may expand due to heat, causing springback, which may prevent molding. .

[0071]

According to the method of manufacturing a cushion material made of a resin molded product having a spring structure according to the first aspect of the present invention, the cushion made of a resin molded product having a spring structure having desired physical properties such as load resistance and impact resistance. The material can be easily manufactured in a short time and mass production is possible. Since it is compression-molded, it can be freely processed into individual shapes and sizes. In the case of compound vibration such as vertical vibration or horizontal vibration, it is possible to provide a raised portion on both the front surface and the back surface.

Particularly, by using a female mold made of concrete, PE and P constituting a resin molded product having a spring structure are formed.
Since the raw material resin such as P does not adhere to the mold, the mold release agent which is indispensable in the molding method using the metal mold becomes unnecessary. In addition, the temperature of concrete is more uniform than that of metal, and there is no risk of the surface of the spring structure resin molded product being burnt. Further, since the molding process is simplified and the molding time is shortened, it is possible to mass-produce the cushion material. Furthermore, concrete is easy to adapt to products, has excellent formability, and can be manufactured by simply kneading it and pouring it into a mold. Therefore, the cost of the mold itself is reduced, and it is also possible to manufacture molds with complex shapes. Yes, and the same thing can be easily duplicated.

Further, the thickness of the cushion material and the cushion performance can be easily adjusted by adjusting the stroke at the time of mold clamping and setting the spring structure resin molded product (for example, thickness of wire, material, bulk density, porosity, etc.). Can be changed. Specifically, it is possible to meet various product required characteristics with one type of mold without having to prepare a large number of molds. For example, when it is used in an automobile, a motorcycle, etc., it can be suitably adapted to each model (suspension characteristic). Further, although the material of the cushioning material is constant as a whole, the spring characteristics, the rigidity, etc. can be freely set by applying compression molding to draw the material. For example, depending on the type of automobile or motorcycle (for example, for touring, for road racing, for motocross, etc.), the spring characteristics can be made variable without complicated steps. Further, for example, in the case of motocross, the impact on the buttocks is alleviated, so that it is possible to drive while sitting on the seat, and the running stability is improved.

Further, it is simpler than the secondary processing of urethane foam, and the T
Since highly toxic raw materials such as DI are not used, no toxic gas is generated during manufacturing and the working environment is good.

Further, according to the present manufacturing method, a resin such as PE which is a recycled resin for reuse of thermoplastic resin edible oil packaging containers and discarded agricultural plastic films is recycled as a high value-added product. While being able to
The cushion material itself, which is a resin molded product having a spring structure, can be regenerated many times by remelting.
In this way, it is excellent in recyclability and is designed so as not to give a load to the environment after use. Moreover, since recycled resin can be used, it can be manufactured at low cost.

The cushion material made of the spring structure resin molded product manufactured by this manufacturing method is excellent in durability and settling resistance, has a small local depression, and does not have a feeling of bottoming or rocking. In addition, when sitting, it is possible to evenly receive the load and disperse the pressure on the entire body-contacting area, so fatigue does not occur even when used for a long time,
Improves sitting comfort. In this way, a unique sitting comfort not available with urethane foam is obtained.

Since the cushion material made of the resin molded product having the spring structure manufactured by this manufacturing method has a high spring property, the coil material conventionally installed under the seat of an automobile or a motorcycle as a kickback countermeasure. No spring is needed. Therefore, while having a simple structure,
The lower center of gravity improves the stability of automobiles and motorcycles.

Since the cushion material made of the resin molding of the spring structure manufactured by the present manufacturing method is a structure having completely continuous voids, it has excellent air permeability. Therefore, it does not get damp. Further, since the air for cooling and heating can be ventilated from the cooling and heating duct through the cushion material, the seat and the like of the motorcycle and the like can be provided with the cooling and heating function. Furthermore, since it is strong in water and has no problem even if it gets wet with rain, it is suitable as a seat for motorcycles. It can also be washed with water and dries quickly.

According to the female mold made of concrete described in claim 2, it is possible to suitably obtain the female mold used in the method for manufacturing the cushion material made of the spring structure resin molded product.

From the above, the method of manufacturing the cushion material made of the resin molded product having the spring structure according to the present invention is as follows.
Seats for automobiles, motorcycles, bicycles, trains or airplanes, saddles for riding, chairs, sofas, beds, etc.
As a method of manufacturing a cushion material made of a resin molded product having a spring structure, which can be suitably used as a substitute material for a conventional urethane foam when a person sits, sleeps, or rides, with or without vibration. It is suitable.

The embodiment of the method for manufacturing the cushion material made of the spring-structured resin molded product according to the present invention is not limited to the above, and various forms can be adopted within the technical scope of the present invention. It is a thing. Further, modifications and the like can be added without departing from the technical idea of the present invention, and those modifications,
Equivalents and the like are also included in the technical scope of the present invention.

[Brief description of drawings]

FIG. 1 is a perspective view of a cushion member 1 and a base 4.

2A and 2B are a cushion material 1 and a base 4.
FIG. 3 is a front view and a rear view of FIG.

FIG. 3 is a side view of a motorcycle 10 including a seat including the cushion material 1.

4A and 4B are perspective views of the base 4 viewed from different angles.

FIG. 5 is an explanatory view showing the first stage of the compression molding process of the cushion material 1.

FIG. 6 is an explanatory view from another angle showing the first stage of the compression molding process of the cushion material 1.

FIG. 7 is an explanatory diagram showing a second stage of the compression molding process of the cushion material 1.

FIG. 8 is an explanatory view from another angle showing the second stage of the compression molding process of the cushion material 1.

FIG. 9 is an explanatory view showing a third stage of the compression molding process of the cushion material 1.

FIG. 10 is an explanatory diagram showing a step of attaching the cushion material 1 to the base.

FIG. 11 is a schematic view showing steps of a method for manufacturing a spring-structured resin molded product 30.

FIG. 12 is a perspective view showing a method for manufacturing a spring structure resin molded product 30.

FIG. 13 is an example showing another method of manufacturing the spring structure resin molded product 30.

FIG. 14 is an example showing still another method of manufacturing the spring structure resin molded product 30.

15 (a), (b) and (c) are cross-sectional views showing another embodiment of the spring structure resin molded product 30. FIG.

16 (a), (b) and (c) are sectional views showing still another embodiment of the spring structure resin molded product 30. FIG.

17A and 17B are a rear view and a perspective view of the molding die 622.

18 (a), (b) and (c) are cross-sectional views showing another embodiment of the spring structure resin molded product 30 or the wire 31.

19 (a) and 19 (b) are sectional views showing another embodiment of the cushioning material 1. FIG.

20 (a) and 20 (b) are sectional views showing still another embodiment of the cushioning material 1. FIG.

FIG. 21 is an explanatory view showing another embodiment of the compression molding step of the cushion material 1.

22 (a) and 22 (b) are explanatory views showing still another embodiment of the compression molding process of the cushion material 1. FIG.

[Explanation of symbols]

1 cushion material 2 upper sheet 3 Lower sheet 4 Base 5 Vinyl Leather 10 Motorcycle 11 female mold 12 cavity 13 Hot water supply device 14 Male type 15 Pantograph jack 16 Heat cutter 20 Extruder 21 Hopper 22 molding die 23 take-up machine 24 pick-up roll 25 bath 26 Take-up roll 27 Cutting device 30 Spring structure resin molded product 31 Stroke 32 Bali

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) // B29L 31:58 B29L 31:58 (72) Inventor Maki Shirai Nishigotanda 2-26, Shinagawa-ku, Tokyo No. 9 Inside Ein Engineering Co., Ltd. (72) Inventor Yuichiro Nakamura 2 26-9, Nishigotanda, Shinagawa-ku, Tokyo F-Term inside Ain Engineering Co., Ltd. (reference) 3B096 AD04 AD07 BA01 4F202 AA03 AE07 AG02 AH26 AJ01 CA09 CA17 CA30 CB01 CD30 CK11 CL02 CN01 CN05 4F207 AA03 AG02 AH26 KA01 KA17 KK51 KK82 KW23 KW26 KW41

Claims (2)

[Claims] 1. Random loops or curls of solid and / or hollow continuous filaments and / or short filaments made of at least a thermoplastic resin are contact-entangled with each other on a female mold made of concrete. Placing a three-dimensional structure having voids of a predetermined bulk density formed by aggregating, heating the female mold and / or the three-dimensional structure under temperature conditions necessary for softening the three-dimensional structure, A method for manufacturing a cushioning material composed of a spring-structured resin molded product, characterized in that the three-dimensional structure is clamped with a male mold, and the three-dimensional structure is cured by cooling. 2. A predetermined bulk density formed by contact entanglement of adjacent linear filaments of random loops or curls of solid and / or hollow continuous filaments and / or short filaments made of at least a thermoplastic resin. A female mold made of concrete used for molding a spring structure resin molded product composed of a three-dimensional structure having voids, in which concrete is injected into a mold frame modeled after the original shape of the spring structure resin molded product. A female mold made of concrete characterized by being hardened.