JP2004216731A - Method for producing integrated foamed molded article with fastener - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing an integrated foamed molded article with a fastener which sufficiently increases the fastener attaching strength of a foamed molded article such as urethane foam with a fastener. <P>SOLUTION: After a fastener 20 is fitted and held to a rail 40, a urethane raw material liquid is injected and expanded, and the urethane foam is demolded after foamed. In the foaming process, urethane ready to foam passes through a communication part 42 or a release part 26 to sufficiently enter a space 24. At this time, gas such as air in the space 24 flows out through the communication part 42 and the release part 26. Since channels 43 and 33 are formed to the side of the rail 40 and the cavity surface of a lower mold 30, the gas flowing out of the communication part 42 passes through the channels 43 and 33 to be diffused through the interfacial part between the urethane foam and the cavity surface. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for manufacturing an integrated foam molded article with a fastener, which integrally forms a fastener such as a hook-and-loop fastener with a foam molded article such as a vehicle seat pad.
[0002]
[Prior art]
2. Description of the Related Art A cushioning material in which a skin material such as cloth is attached to urethane foam is used for seats and interior parts of doors of various vehicles. The urethane foam and the skin material may be detachably assembled by a fastener such as a hook-and-loop fastener fixed to the urethane. In particular, when the suspended design is provided on the sheet, as shown in FIG. 5, the suspended design is positioned at the concave streak portion recessed from the outer surface of the molded product. FIG. 5A is a perspective view of the sheet 1, and FIG. 5B is a cross-sectional view taken along the line BB of FIG. 5A.
[0003]
The seat 1 includes a seat cushion 2, a seat back 3 and a headrest 4, and a hanging design 5 is provided on an upper surface of the seat cushion 2 and a front surface of the seat back 3. The sheet 1 is obtained by covering a skin material 7 on a urethane foam 6. The hanging design 5 is a concave stripe pattern that is recessed from the sheet surface, and a fastener 8 is provided on the urethane foam 6 so as to face the groove bottom surface of the hanging design 5. A fastener 9 provided on the skin material 7 is coupled to the fastener 8. The fastener 8 is formed integrally with the urethane foam 6. Each of the fasteners 8 and 9 includes a belt-shaped base and an engagement protrusion (hook or loop) provided on one surface (fastening surface) of the base. The fasteners 8 and 9 are connected to each other by the engagement of the hook and the loop.
[0004]
In order to dispose the fastener on the surface of urethane foam, integral molding of urethane and fastener has been conventionally performed. In this case, in order to prevent the liquid foaming raw material from penetrating and attaching to the fastener surface of the fastener, for example, cover the fastening surface with a rail having a concave cross-section and then pour the liquid foaming resin raw material into a molding die. I have to.
[0005]
6 and 7 illustrate this conventional method. FIG. 6 is a sectional view of a mold after foaming, and FIG. 7 is a perspective view showing an engagement relationship between a fastener 8 and a rail 12. In this method, a fastener 8 is attached to a urethane foam 6 which is a foam molded product by integral molding using a molding die composed of a lower mold 10 and an upper mold 11.
[0006]
A rail 12 is fixed to a lower mold 10 of a molding die, and a fastener 8 is held on the rail 12. The rail 12 has an upward U-shaped cross section, and the engagement projection 8b is naturally directed downward as shown in FIG. 7, and is disposed in the rail 12, and the anchor 8c is directed upward. 8a indicates a base.
[0007]
After the urethane is foamed, the molded article is released from the upper part of FIGS.
[0008]
Japanese Patent Application Laid-Open No. 2001-190311 describes an improved example of such a molding method.
[0009]
[Patent Document 1]
JP 2001-190311 A
[Problems to be solved by the invention]
SUMMARY OF THE INVENTION An object of the present invention is to provide a method of manufacturing an integrated foam molded article with a fastener, in which the bonding force between the fastener and the resin foam molded article is sufficiently high.
[0011]
[Means for Solving the Problems]
The manufacturing method of the integrated foamed article with a fastener according to the present invention is a method of manufacturing an integrated foamed article with a fastener, in which the front side is a fastening surface and the back side is a joint surface with the foamed molded article by integral molding. A method, wherein a rail having a concave cross-sectional shape is provided on a cavity surface of a molding die, the fastener is fitted to the rail so that the back side of the fastener is covered with the rail, and the inside of the mold is inserted. In the method for producing a molded article with a fastener that supplies and expands a foamed resin material and then removes the mold, the fastener is provided with a void that opens toward the joint surface and the side surface of the fastener, The rail is provided with a communicating portion for communicating the inside of the cavity with the inside of the cavity.
[0012]
According to the manufacturing method of the integrated foamed article with the fastener of the present invention, the resin being foamed enters into the space of the fastener, and the bonding strength between the fastener and the resin foam molded article is sufficiently high. In addition, the gas such as air remaining in the empty space is discharged to the outside of the fastener through the communication portion instead of the resin.
[0013]
In order to make it easier to discharge the gas flowing out of this space, a groove connected to the communicating portion may be provided on the cavity surface of the molding die.
[0014]
A notch is preferable as the communication part.
[0015]
When the vacant space is open toward both side surfaces of the fastener, it is preferable to provide communication portions on both side surfaces of the rail. In particular, a void facing one side of the fastener and a void facing the other side are provided, and when these voids are isolated from each other, by providing communication portions on both side surfaces of the rail, The foamed resin can be reliably inserted into each of the voids.
[0016]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments will be described with reference to the drawings. 1 (a) and 1 (b) are perspective views of a fastener, FIG. 2 is an explanatory perspective view of engagement between the fastener and a rail of a mold, and FIG. 3 (a) is an explanatory sectional view of engagement of the fastener and a rail. 3 (b) is a cross-sectional view of a manufactured integrated foamed product with a fastener, and FIG. 4 is a cross-sectional view showing another embodiment.
[0017]
The fastener 20 used in the embodiment of FIGS. 1 to 4 has a structure in which a large number of substantially hollow rectangular parallelepiped block portions 21 are arranged in one row. The fastener 20 has a fastening surface on the lower surface side in FIG. 1, and a plurality of hook-shaped engaging protrusions 22 project from the fastening surface. By engaging the hook-shaped engaging projections 22 with the fastener loops of the skin material (not shown), the skin material and the urethane foam are connected.
[0018]
The upper surface side of the fastener 20 in FIG. 1 is a joint surface with the urethane foam, and an anchor 23 protrudes from this joint surface.
[0019]
Both sides of the hollow block portion 21 of the fastener 20 are open as a whole, and an internal space 24 faces both sides of the fastener 20. In this embodiment, a partition 25 extending in the longitudinal direction of the fastener 20 is provided in the block portion 21, and the spaces 24 on both sides are isolated by the partition 25. An opening 26 is provided on the joint surface (anchor upright surface) of the fastener 20 with the urethane foam to allow the void 24 to communicate with the outside of the fastener 20.
[0020]
A rail mounting seat 32 is protruded from a cavity surface of a lower mold 30 of a molding die for molding urethane foam. The rail 40 is mounted on the rail mounting seat 32. The rail 40 has a concave cross-sectional shape having a pair of side walls 41, 41. Each of the side walls 41 is provided with a communication portion 42 formed of a notch. The communication part 42 communicates the inside and outside of the rail 40. On the outer side surface of the rail 40, a groove 43 communicating with the communication portion 42 is provided. On the cavity surface of the lower die 30, a groove 33 connected to the groove 43 is provided.
[0021]
As shown in FIG. 3A, after the fastener 20 is fitted and held on the rail 40, a urethane raw material liquid is injected and foamed, and after the foaming, the urethane foam is released. During this foaming, the urethane being foamed sufficiently enters the space 24 through the communication portion 42 or the open portion 26. At this time, gas such as air in the space 24 flows out through the communication part 42 and the opening part 26. For this reason, the urethane foam 6 and the fastener 20 are sufficiently engaged with each other as shown in FIG. 3B, and the connection strength between the fastener 20 and the urethane foam 6 is sufficiently increased.
[0022]
Particularly, in this embodiment, since the grooves 43 and 33 are provided on the side surface of the rail 40 and the cavity surface of the lower mold 30, the gas flowing out from the communication portion 42 passes through the grooves 43 and 33 and is urethane. Since the interface between the foam and the cavity surface is diffused, bubbles are prevented from remaining in the urethane foam 6 near the fastener 20, especially near the anchor 23. Thereby, the bite between the fastener 20, particularly the anchor 23, and the urethane foam 6 becomes strong, and the adhesive strength between the fastener 20 and the urethane foam 6 becomes sufficiently high.
[0023]
In the above embodiment, the rail mounting seat 32 is provided on the bottom surface of the lower die as shown in FIG. 6, but the rail mounting seat 32A is provided on the side surface of the lower die as in the lower die 30A of FIG. The rail 40 may be mounted on the rail mounting seat 32A. In this case, the groove 33A extends upward along the cavity surface of the lower mold 30A, and extends to near the mating surface with the upper mold 31. As a result, the gas flowing out of the space 24 diffuses smoothly to the upper part of the mold.
[0024]
This embodiment also allows the urethane foam to sufficiently penetrate into the voids 24, so that the fastener is strongly connected to the urethane foam.
[0025]
The above embodiment is an example of the present invention, and the present invention is not limited to this. For example, the shapes of the fasteners and the engagement projections of the fastener may be other than those illustrated. The present invention can also be applied to the production of a molded article with a fastener other than urethane foam.
[0026]
【Example】
Example 1
A urethane foam with a fastener was manufactured according to the method of the present invention using a SF-9 equivalent fastener manufactured by Sumitomo 3M Co., Ltd., and cut out to dimensions shown in FIGS.
[0027]
The end of the urethane foam side of this sample was chucked as shown in FIG. 8 (b), the center of the fastener 20 in the longitudinal direction was pulled, and the peel strength was measured to be 60N.
[0028]
Comparative Example 1
A urethane foam with a fastener was manufactured by a conventional method using a conventional product as a fastener, and the same measurement as in Example 1 was performed. As a result, the peel strength was 30N.
[0029]
【The invention's effect】
As described above, according to the present invention, the fastener mounting strength of a foam molded product such as urethane foam with a fastener can be made sufficiently high.
[Brief description of the drawings]
FIG. 1 is a perspective view of a fastener.
FIG. 2 is an explanatory perspective view of engagement between a fastener and a rail of a mold.
FIG. 3A is a cross-sectional view for explaining the engagement between a fastener and a rail, and FIG. 3B is a cross-sectional view of a manufactured integrated foamed product with a fastener.
FIG. 4 is a cross-sectional view showing another embodiment.
5A is a perspective view of an automobile seat, and FIG. 5B is a cross-sectional view taken along line BB in FIG. 5A.
FIG. 6 is a cross-sectional view illustrating a method of forming the sheet of FIG.
FIG. 7 is a perspective view showing a method for forming the sheet of FIG. 5;
FIG. 8 is an explanatory diagram showing an embodiment.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Sheet 5 Hanging design 6 Urethane foam 8,20 Fastener 12,40 Rail 21 Block part 22 Engagement projection 23 Anchor 24 Void 25 Partition wall 26 Opening part 30 Lower mold 32 Rail mounting seats 33,33A, 43 Groove

Claims (8)

A method for manufacturing an integrated foam molded product with a fastener, in which a front surface is a fastening surface and a back surface is a joint surface with the foam molded product, the fastener being integrally molded with the foam molded product,
A rail having a concave cross-sectional shape is provided on the cavity surface of the molding die, and the fastener is fitted to the rail so that the back side of the fastener is covered with the rail,
In the method for producing an integrated foamed product with a fastener to supply and foam a foamed resin material in the mold and then remove the mold,
The fastener is provided with a void that opens toward the joining surface and the side surface of the fastener,
A method for manufacturing an integrated foam molded article with a fastener, characterized in that a communication portion for communicating the inside of the space with the inside of the cavity is provided on the rail. 2. The method according to claim 1, wherein the communicating portion comprises a cut-out portion. The vacant space according to claim 1 or 2, wherein the space is open toward both side surfaces of the fastener.
The method for manufacturing an integrated foamed product with a fastener, wherein the communication portions are provided on both side surfaces of the rail. 4. The integrated foam molding with a fastener according to claim 3, wherein a void facing one side of the fastener and a void facing the other side are provided, and the voids are separated from each other. Product manufacturing method. The method according to any one of claims 1 to 4, wherein a groove connected to the communication portion is provided on a cavity surface of the molding die. The integrated foamed product with a fastener according to any one of claims 1 to 5, wherein a plurality of anchors are provided on the joining surface of the fastener with a plurality of anchors projecting at intervals in the longitudinal direction of the fastener. Production method. The method according to claim 6, wherein the space is opened between the anchors toward the joint surface. The method according to any one of claims 1 to 7, wherein the foamed molded product is urethane.

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