JP2005125695A - Method and apparatus for producing foamed molding, and molding auxiliary material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To simply at a low cost prevent or reduce the occurrence of an air bank when a cushion material is molded. <P>SOLUTION: A flow direction adjustment fin 16 is formed in a molding auxiliary material 15 molded integrally with the cushion material 11. When the material 15 is set in a mold 17, the fin 16 is arranged upstream from a recessed part 24a (difficult inflow part) into which a foamable raw material is supplied difficultly in a cavity. When the raw material injected in the mold 17 is foamed and made to flow, the flow direction of the raw material is adjusted toward the recessed part 24a on the upstream side of the concave part 24a by the fin 16. In this way, the raw material is packed enough in the recessed part 24a, and the occurrence of the air bank in the recessed part 24a is reduced or prevented. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a method and an apparatus for producing a foam molded product, in which a foamable raw material is filled in a cavity by molding and flowing a liquid foamable raw material in a cavity of a mold, and molding of the foam molded product. It is invention regarding the molding auxiliary material used for.

  In general, foam molded products such as polyurethane having high elasticity are used as cushioning materials for automobile seats. This foamed molded product is obtained by injecting a liquid foamable raw material (for example, a mixed raw material of a polyol-based resin raw material and an isocyanate-based resin raw material mixed with a foaming agent such as water) into the cavity of the molding die. The foamable raw material is foamed, and the foamable raw material is caused to flow by volume expansion accompanying the foaming, thereby filling the entire interior of the cavity with the foamable raw material to form a foam molded product.

  In general, the cavity shape of the mold varies depending on the shape of the foam-molded product, and the cavity shape may be uneven with the foaming raw material inherently difficult to flow. In such a mold, when the foamable raw material injected into the cavity is foamed and fluidized, an air pool is easily generated where air (air) remains in a portion where the foamable raw material is difficult to flow. A lack of air will occur in the foamed molded product due to air accumulation.

As a countermeasure, for example, as described in Patent Document 1 (Japanese Patent Application Laid-Open No. 2003-19719), when molding a foam molded product, the air in the cavity of the molding die is sucked into the cavity. There is one in which the injected foamable raw material is foamed and filled.
JP 2003-19719 (second page, etc.)

  However, when manufacturing a foamed molded article by the manufacturing method of Patent Document 1 described above, it is difficult to ensure the airtightness of the mold because fine dust and foreign matter adhere to the split surface of the mold at the actual manufacturing site. It is actually quite difficult to effectively suck the air in the cavity.

  The present invention has been made in view of such circumstances. Therefore, the object of the present invention is to prevent or reduce the occurrence of air stagnation at the time of molding a foam molded product at low cost and easily. An object of the present invention is to make it possible to easily prevent or reduce a lack of thickness due to air accumulation in a foam molded product at low cost.

  In order to achieve the above object, the invention according to claims 1, 9, and 14 of the present invention foams a liquid foamable raw material injected into a mold cavity in a state where a molding auxiliary material is set in the mold. In addition, when a foamable raw material is molded into a cavity by filling the cavity with a foamable raw material to form a foamed molded product in which the molding auxiliary material is integrated, air stagnation tends to occur in the cavity of the molding auxiliary material. The flow direction adjusting means for adjusting the flow direction of the foamable raw material is provided at a position corresponding to or near the portion where the foamable raw material is expected, and the molding auxiliary material is set in the cavity to form the foamable raw material. When the foam is caused to foam and flow, the flow direction adjusting means adjusts the flow direction of the foamable raw material in a direction that reduces or prevents the occurrence of air accumulation.

  In this way, the flow direction adjusting means can be arranged simply by setting the molding auxiliary material in the cavity of the mold, and the flow direction adjusting means reduces the occurrence of air accumulation in the flow direction of the foamable raw material. Or it can be adjusted in the direction to prevent, so even if the shape of the cavity with unevenness, which is inherently difficult for the foamable raw material to flow, the foamable raw material should flow evenly throughout the cavity and be filled Can do. This makes it possible to prevent or reduce the occurrence of air stagnation in the cavity when molding a foam molded product easily and at low cost, and to reduce the occurrence of thinning due to air stagnation in the foam molded product at low cost. And it can be easily prevented or reduced.

  In this case, the flow direction adjusting means provided separately from the molding auxiliary material may be attached to the molding auxiliary material, but the flow direction adjusting means may be attached to the molding auxiliary material as in claims 2, 10 and 15. It is good to form using the edge part. If it does in this way, a flow direction adjustment means can be provided by a simple method which only changes the specification of the edge of a forming auxiliary material.

  Furthermore, as in claim 3, when the mold is composed of an upper mold, a lower mold, and a middle mold disposed between them, the molding auxiliary material is attached to the middle mold. good. Generally, the foamable raw material is injected into the cavity of the lower mold and flows from the cavity of the lower mold toward the cavity of the upper mold by volume expansion accompanying foaming. In addition, the air pool is likely to occur at the upper part of the upper mold cavity. For this reason, if the molding auxiliary material is attached to the middle mold and the flow direction adjusting means is arranged at a middle position between the cavities formed by the lower mold and the upper mold, the foamable raw material is moved upward from the cavity of the lower mold. By adjusting the flow direction of the foamable raw material at the stage of flowing into the mold cavity, it is possible to effectively create a flow of the foamable raw material in a direction in which no air pool is generated in the cavity of the upper mold.

  In addition, as in claims 4 and 11, the flow direction of the foamable raw material is adjusted to a position corresponding to or near a portion of the mold that is likely to cause air accumulation in the cavity. You may make it provide the flow direction adjustment means to do. Even if it does in this way, at the time of shape | molding a foaming molded product, generation | occurrence | production of the air pocket in a cavity can be prevented simply and at low cost.

  Furthermore, as in claim 5, when the mold is composed of an upper mold, a lower mold, and a middle mold disposed between the two molds, the flow direction adjusting means protrudes into the cavity. As such, it may be provided in the middle mold. In this way, the flow direction adjusting means can be disposed at an intermediate position between the cavity formed by the lower mold and the upper mold, so that the foamable raw material flows from the lower mold cavity to the upper mold cavity. By adjusting the flow direction of the foamable raw material, it is possible to effectively create a flow of the foamable raw material in a direction in which no air pool is generated in the upper mold cavity.

  Further, as in claim 6, the flow direction adjusting means is disposed upstream of the difficult inflow portion in which the foamable raw material does not easily flow in the cavity, and the flow of the foamable raw material upstream of the difficult inflow portion. You may make it adjust so that a direction may face the direction of a difficult inflow part. Alternatively, as in claim 7, the flow direction adjusting means is disposed downstream of the difficult inflow portion, and the flow direction of a part of the foamable raw material is changed to the direction of the difficult inflow portion on the downstream side of the difficult inflow portion. You may make it adjust so that it may flow backward. In any case, it is possible to prevent or reduce the occurrence of air accumulation in the difficult inflow portion by causing the foamable raw material to flow into the difficult inflow portion.

  In addition, as in claim 8, the flow direction adjusting means may be formed to a length extending in a region of 20 to 95% of the flow path width of the cavity. If the length of the flow direction adjusting means in the cavity flow path width direction is shorter than 20% of the cavity flow path width, the flow direction of the foamable raw material may not be sufficiently adjusted. If it is longer than 95% of the road width, the flow path of the foamable raw material becomes too narrow, and the fluidity / fillability of the foamable raw material may be deteriorated. Therefore, if the length of the flow direction adjusting means in the cavity flow path width direction is set to 20 to 95% of the cavity flow path width, the flow of the foamable raw material is appropriately secured and the foamability of the foamable raw material is filled. The flow direction of the foamable raw material can be adjusted in a direction that reduces or prevents the occurrence of air accumulation.

  Further, when the flow direction adjusting means is provided in the mold, the flow direction adjusting means is formed of a material having releasability that is difficult to adhere to the foam molded product, and is provided in the mold. You may do it. In this way, at the time of mold release, the flow direction adjusting means can be left on the mold side, so the same flow direction adjusting means can be used over and over again, each time a foam molded product is molded. This saves you the trouble of installing new flow direction adjustment means.

  Alternatively, as in the thirteenth aspect, the flow direction adjusting means is formed of a material that is easily fixed to the foamed molded product, and is provided in the mold so as to be taken out integrally with the foamed molded product at the time of mold release. Anyway. If it does in this way, a flow direction adjustment means can be integrated with a foam-molded product, and this can be functioned also as a reinforcing material etc. of a foam-molded product.

  Further, in the case where the flow direction adjusting means is provided in the molding auxiliary material, the molding auxiliary material is formed by sewing a cloth-like member cut into a predetermined shape as in claim 16, and a plurality of cloth-like members are formed. The flow direction adjusting means may be formed using a portion where the edges of the cloth-like members are overlapped or a portion where the edges of the cloth-like member are folded back. In this way, the bending direction of the flow direction adjusting means can be increased even if the forming auxiliary material is formed of a cloth-like member, so that the flow direction adjusting means is easily pushed down by the flow of the foamable raw material. This can be prevented, and the function of adjusting the flow direction of the foamable raw material can be sufficiently provided. In addition, the flow direction adjusting means can be easily formed on the edge of the molding auxiliary material simply by changing the cutting shape (edge shape) of the cloth-like member and the position of the seam.

  Further, as in claim 17, the molding auxiliary material is formed of a material having innumerable fine voids therein that prevent permeation of the foamable raw material in the thickness direction and allow air to flow in the surface direction. It is good to do so. In this way, the volume of the space between the molding auxiliary material and the foamable raw material is reduced while preventing the liquid of the foaming raw material from permeating through the molding auxiliary material in the thickness direction. Along with this, air remaining in the space can be released in the surface direction of the molding auxiliary material and discharged, so that air accumulation can be prevented from occurring between the molding auxiliary material and the foamable raw material.

  Hereinafter, three examples 1 to 3 in which the present invention is applied to a cushion material for a seat back (back portion of a seat) of an automobile will be described.

  A first embodiment of the present invention will be described with reference to FIGS. First, a schematic configuration of the cushion material 11 for the seat back will be described with reference to FIGS. 1 and 2. Here, FIG. 1 is a perspective view of the cushion material 11 viewed from the back side, and FIG. 2 is a cross-sectional view taken along the line AA of FIG.

  As shown in FIGS. 1 and 2, the cushion material 11 is a foamed molded product such as polyurethane, and is mixed with a liquid foamable raw material (for example, a polyol-based resin raw material and an isocyanate-based resin raw material in a molding die 17 described later). A foamable raw material in which a foaming agent such as water is mixed into the raw material) is foamed and fluidized to fill the mold 17 with the foamable raw material and molded. A center portion 12 that supports the back of a seated person is provided in the central portion on the front side of the cushion material 11, and side portions 13 that extend in the vertical direction are provided on the left and right sides of the center portion 12. The left and right side parts 13 are connected via an upper part 14 at least at the upper part of the rear part. Here, the front-rear direction and the left-right direction of the cushion material 11 refer to the front and back directions and the left-right direction when a seated person sits, and the up-down direction refers to the vehicle body when the cushion material 11 is attached to the vehicle body. It shall point in the up-down direction.

  In addition, as shown in FIG. 2, a portion of the cushion material 11 that is exposed to a molding concave portion (a portion into which a later-described middle mold 20 is fitted) formed on the back side of the cushion material 11 is a reinforcing molding material 15 for reinforcement. It is arranged so as to cover and is integrally formed. The molding auxiliary material 15 is formed by sewing cloth-like members cut into a predetermined shape, and corresponds to a portion of the molding auxiliary material 15 where air accumulation is expected to occur in the molding die 17. A fin-like flow direction adjusting fin 16 (flow direction adjusting means) for adjusting the flow direction of the foamable raw material is provided at the position or a position in the vicinity thereof.

  This flow direction adjusting fin 16 is formed by using a part in which a plurality of edges of the cloth-like member forming the molding auxiliary material 15 are overlapped or a part in which the edges of the cloth-like member are folded and overlapped, Bending strength is enhanced. In addition, the cloth-like member forming the molding auxiliary material 15 has innumerable fine voids inside to prevent the permeation of the foamable raw material in the thickness direction and allow air to flow in the thickness direction and the surface direction. A material (for example, a nonwoven fabric such as felt) is used.

  Next, the manufacturing method of the cushion material 11 is demonstrated based on FIG. 3 thru | or FIG. Here, FIG. 3 is a perspective view showing a state when the mold 17 is opened, and FIG. 4 is a cross-sectional view taken along the line BB of FIG. 3 (a cross-sectional view of the closed mold 17 cut back and forth). 5 is a cross-sectional view taken along the line CC of FIG. 3 (a cross-sectional view of the closed mold 17 cut in the left-right direction), and FIG. 6 is a peripheral portion of the flow direction adjusting fin 16 in the mold 17. FIG. 6 is an enlarged cross-sectional view (partially enlarged cross-sectional view of the closed mold 17 cut in the left-right direction).

  As shown in FIGS. 3 to 5, the molding die 17 for molding the cushion material 11 is arranged so that the cushion material 11 is molded with the front surface side (side facing the back of the seated person) facing downward, and the upper die 18, a lower mold 19, and a middle mold 20 disposed between them. The upper die 18 is attached to the lower die 19 via the hinge mechanism 21 so as to be capable of opening and closing, and the middle die 20 is attached to the upper die 18 side. The lower mold 19 is provided with a center cavity 22 for molding the center portion 12 of the cushion material 11 and a side cavity 23 for molding the lower portion of the side portion 13 (the waist side of the seated person). The upper mold 18 is provided with a cavity 24 for molding the upper portion of the side portion 13 (the shoulder side of a seated person) and the upper portion 14. Here, the vertical direction of the mold 17 refers to the direction of gravity, the front-rear direction refers to the direction connecting the open end side of the open / close rotation of the mold 17 and the hinge side, and the left-right direction refers to the front-rear direction. And a direction perpendicular to each other in a horizontal plane (see FIG. 3).

  In the molding process of the cushion material 11, as shown in FIG. 3, first, the molding auxiliary material 15 is mounted on the middle mold 20 of the molding die 17. Thereafter, the liquid first foamable raw material P1 is injected from a not-shown injection nozzle into a predetermined location (for example, two locations on the left and right sides) of the side cavity 23 of the lower die 19, and a predetermined location ( For example, the liquid second foamable raw material P2 is injected into the front and rear two places. Here, when the side part 13 of the cushion material 11 is formed of a foam harder than the center part 12, the first foamable raw material P1 is a foam harder than the second foamable raw material P2. A foamable raw material that can be molded is used.

  After the injection of the first foamable raw material P1 and the second foamable raw material P2 is completed with the molding auxiliary material 15 set in the molding die 17, the molding die 17 is closed (the upper die 18 and the middle die 20). The first foamable raw material P1 and the second foamable raw material P2 are foamed, and the first foamable raw material P1 and the second foamable raw material are expanded by volume expansion accompanying the foaming. P2 is allowed to flow.

  At that time, as shown in FIGS. 4 and 5, the first foamable raw material P <b> 1 flows so as to spread in the side cavity 23 of the lower mold 19 due to volume expansion accompanying foaming, and the side cavity of the lower mold 19. The fluid flows from 23 to the cavity 24 of the upper mold 18 and is filled in the side cavity 23 of the lower mold 19 and the cavity 24 of the upper mold 18. On the other hand, as shown in FIG. 5, the second foamable raw material P <b> 2 flows so as to spread in the center cavity 22 of the lower mold 19 due to volume expansion accompanying foaming, and fills the center cavity 22 of the lower mold 19. It will be done.

  In the cushion material 11 of the first embodiment, the convex portion 13a (see FIG. 1) is formed on the upper portion of the side portion 13 (that is, the portion formed by the cavity 24 of the upper mold 18). The cavity 24 of the upper mold 19 is formed with a concave portion 24a (see FIG. 4). When the flow direction adjusting fin 16 is not provided in the molding auxiliary material 15, the first foamable raw material P <b> 1 simply foams and flows toward the upper side of the molding die 17, and the upper mold 18, which is a difficult inflow portion, is formed. The concave portion 24a is not filled with the first foamable raw material P1, and air stagnation tends to occur in the concave portion 24a.

  Therefore, in the first embodiment, when the molding auxiliary material 15 is set in the molding die 17, the flow direction adjusting fin 16 formed at the edge of the molding auxiliary material 15 is formed on the concave portion 24a (difficult inflow portion). Arranged on the upstream side (upstream side with respect to the flow direction of the first foamable raw material P1, and on the lower side in FIGS. 4 and 5), the flow direction adjusting fin 16 causes the upstream side of the concave portion 24a. The flow direction of the first foamable raw material P1 is adjusted so as to be directed toward the concave portion 24a to reduce or prevent the occurrence of air accumulation.

  Specifically, as shown in FIGS. 5 and 6, the flow of the first foamable raw material P <b> 1 formed by the lower mold 19 and the upper mold 18 when viewed in the cross-section in the left-right direction of the mold 17. On the upstream side of the difficult inflow portion (concave portion 24a) of the passage (cavity), the flow direction adjusting fin 16 blocks the portion on the mold surface side of the middle mold 20 in the flow path of the first foamable raw material P1, The flow path of the first foamable raw material P1 is narrowed so that it flows along the mold surface of the upper mold 18 of the mold 17. For this reason, the first foamable raw material P1 flows when the first foamable raw material P1 flows from the side cavity 23 of the lower mold 19 to the cavity 24 of the upper mold 18 when viewed in the left-right cross section of the mold 17. Due to the pressure of the foamable raw material P1, the flow direction adjusting fin 16 is displaced obliquely upward as indicated by the solid line from the free state position shown by the two-dot chain line in FIG. The flow direction is changed to the upward direction or the diagonally upper right direction, and the flow direction is adjusted so as to flow along the left and right mold surfaces of the upper mold 18 so that the first foamable raw material P1 is difficult to flow in (concave part 24a). It starts to flow in the direction. Thereby, the 1st foamable raw material P1 is fully filled also into the difficult inflow part (concave part 24a), and it is reduced or prevented that an air pool arises in the concave part 24a.

  Furthermore, as shown in FIG. 4, when viewed in a cross-section in the front-rear direction of the mold 17, the first foamable raw material P <b> 1 bypasses the flow direction adjusting fin 16 and is on the front side of the upper mold 18 ( The amount of fluid flowing along the mold surface on the left side and flowing in the direction of the difficult inflow portion (concave portion 24a) increases, and this also prevents the air accumulation in the hard inflow portion (concave portion 24a). There is also an effect of creating a flow of the foamable raw material P1.

  Further, as shown in FIG. 6, the flow direction adjusting fin 16 is in the cavity channel width direction when in the free state (the state indicated by the two-dot chain line in FIG. 6) not pressed by the first foamable raw material P1. The length t2 is set to be 20 to 95% of the cavity flow path width t1. If the length t2 of the flow direction adjusting fin 16 in the cavity flow path width direction is shorter than 20% of the cavity flow path width t1, the flow direction of the first foamable raw material P1 may not be sufficiently adjusted. If it is longer than 95% of the cavity flow path width t1, the flow path of the first foamable raw material P1 becomes too narrow and the fluidity / fillability of the first foamable raw material P1 may be deteriorated. . Accordingly, by setting the length t2 of the flow direction adjusting fin 16 in the cavity flow path width direction to 20 to 95% of the cavity flow path width t1, the flow path of the first foamable raw material P1 is appropriately secured. The flow direction of the first foamable raw material P1 can be adjusted in a direction to reduce or prevent the occurrence of air accumulation while ensuring the filling property of the first foamable raw material P1.

  In the first embodiment described above, since the flow direction adjusting fin 16 is formed at the edge of the molding auxiliary material 11 integrally molded with the cushion material 11, the molding auxiliary material is formed when the cushion material 11 is molded. The flow direction adjusting fins 16 can be arranged simply by setting 15 in the mold 17, and the flow direction adjusting fins 16 make it difficult for the foamable raw material to flow by the difficult inflow portion (concave shape) of the upper mold 18. Portion 24a) can also be filled with a foamable raw material. Moreover, it is not always necessary to provide a device for sucking air in the cavity or a device for inclining the mold, and the existing manufacturing facility (mold 17) can be used as it is. Thereby, when the cushion material 11 is molded, the occurrence of air accumulation in the cavity can be prevented or reduced easily and at low cost, and the lack of wall due to the air accumulation in the cushion material 11 can be produced at low cost. And it can be easily prevented or reduced. In addition, you may implement this invention by providing the apparatus which attracts | sucks the air in a cavity, and the apparatus which inclines a shaping | molding die.

  Further, in the first embodiment, the molding auxiliary material 15 is attached to the middle mold 20 and the flow direction adjusting fin 16 is disposed at the middle position of the cavity formed by the lower mold 19 and the upper mold 18. At the stage where the foamable raw material flows from the cavity 23 of the lower mold 19 to the cavity 24 of the upper mold 18, the flow direction of the foamable raw material is adjusted so that air accumulation does not occur in the cavity 24 of the upper mold 18. The flow of foamable raw material can be created effectively.

  Furthermore, in the first embodiment, the length t2 of the flow direction adjusting fin 16 in the cavity flow path width direction is set to 20 to 95% of the cavity flow path width t1, so that the flow path of the foamable raw material is moderate. The flow direction of the foamable raw material can be adjusted to reduce or prevent the occurrence of air accumulation while ensuring the fluidity and filling property of the foamable raw material.

  Further, in the first embodiment, the flow direction adjusting fin 16 is formed by using a portion where a plurality of edge portions of the cloth-like member forming the forming auxiliary material 15 are overlapped or a portion where the edge portions of the cloth-like member are folded and overlapped. The bending strength of the flow direction adjusting fin 16 can be increased even if the molding auxiliary material 15 is formed of a cloth-like member, and the flow direction adjusting fin 16 is caused by the flow of the foamable raw material. It can be prevented from being easily pushed down and can have a sufficient function of adjusting the flow direction of the foamable raw material. Moreover, the flow direction adjusting fins 16 can be easily formed on the edge of the molding auxiliary material 15 simply by changing the cutting shape (edge shape) of the cloth-like member forming the molding auxiliary material 15 or the position of the seam. Can do.

  Further, in the first embodiment, the cloth-like member forming the molding auxiliary material 15 has innumerable fine voids that prevent the foamable raw material from permeating in the thickness direction and allow air to flow in the surface direction. Since the material (for example, non-woven fabric such as felt) is used, the foaming raw material liquid and the foaming material 15 are expanded while preventing the liquid of the foaming raw material from permeating through the molding supplement 15 in the thickness direction. As the volume of the space between the raw materials decreases, the air remaining in the space can be discharged in the surface direction of the molding auxiliary material 15 and discharged, and an air pool is generated between the molding auxiliary material 15 and the foamable raw material. You can avoid it.

  In the first embodiment, the flow direction adjustment fin 16 is formed at the edge of the molding auxiliary material 15, but the flow direction adjustment is performed depending on the position in the mold 17 where air accumulation is likely to occur. The position where the fin 16 is formed may be changed as appropriate. For example, a flow direction adjusting fin may be formed at the center of the molding aid 15.

  In the first embodiment, the flow direction adjusting fin 16 is formed by using a part (edge) of the molding auxiliary material 15, but the flow direction adjusting fin 16 is separately provided from the molding auxiliary material 15. The provided one may be attached to the molding auxiliary material 15. Furthermore, a flow direction adjusting fin may be formed by using a part of another molding auxiliary material, or a flow direction adjusting fin may be attached to another molding auxiliary material.

  Next, Embodiment 2 of the present invention will be described with reference to FIGS. However, substantially the same parts as those in the first embodiment are denoted by the same reference numerals, and the description will be simplified. The parts different from the first embodiment will be mainly described.

  As shown in FIGS. 7 and 8, in the second embodiment, a flow direction adjusting fin 25 (flow direction adjusting means) is provided at the edge of the middle mold 20 of the mold 17. The flow direction adjusting fin 25 is configured such that the tip side portion protrudes into the cavity in a state where the root side portion is embedded and fixed in the edge portion of the middle mold 20. The flow direction adjusting fin 25 is formed of a releasable material (for example, elastic silicone rubber) that is difficult to adhere to the cushion material 11, and the flow direction adjusting fin 25 is formed into a mold when the cushion material 11 is released. 17 (medium mold 20) is left. The flow direction adjusting fin 25 also has a length in the cavity flow path width direction of 20 to 95 of the cavity flow path width in a free state where it is not pushed by the foamable raw material (a state indicated by a two-dot chain line in FIG. 8). % Is set.

  As shown in FIG. 8, the flow direction adjusting fin 25 partially blocks the flow path along the mold surface of the middle mold 20 at an intermediate position of the cavity formed by the lower mold 19 and the upper mold 18. Therefore, when the foamable raw material flows from the side cavity 23 of the lower mold 19 to the cavity 24 of the upper mold 18, the foamable raw material is placed on the left and right mold surfaces of the upper mold 18 by the flow direction adjusting fins 25. Adjusted to flow along, the foamable raw material flows in the direction of the difficult inflow portion (concave portion 24a), and the hard inflow portion (concave portion 24a) is sufficiently filled with the foamable raw material, The occurrence of air stagnation in the difficult inflow portion (concave portion 24a) is reduced or prevented.

  In the second embodiment described above, since the flow direction adjusting fin 25 is provided in the mold 17 (medium mold 20), even when the cushioning material 11 without using the molding auxiliary material 15 is molded, With the flow direction adjusting fin 25 provided, the occurrence of air accumulation in the cavity can be prevented or reduced easily and at low cost, and the lack of wall due to the air accumulation in the cushion material 11 can be achieved at low cost and easily. Can be prevented or reduced.

  Moreover, in the second embodiment, the flow direction adjusting fin 25 is provided in the middle mold 20 of the molding die 17, and the flow direction adjusting fin 25 is disposed at an intermediate position of the cavity formed by the lower mold 19 and the upper mold 18. Since the foamable raw material flows from the cavity 23 of the lower mold 19 to the cavity 24 of the upper mold 18, the flow direction of the foamable raw material is adjusted so that an air pool is formed in the cavity 24 of the upper mold 18. It is possible to effectively create a flow of the foamable raw material in a direction in which it does not occur.

  In the second embodiment, the flow direction adjusting fin 25 is made of a material having a releasing property that is difficult to adhere to the cushion material 11, so that the flow direction adjusting fin 25 is formed when the cushion material 11 is released. It can be left as a part on the mold 17 (medium mold 20) side, and the same flow direction adjusting fin 25 can be used repeatedly many times, so that the component cost can be reduced and the cushion material 11 can be reduced. It is possible to save the trouble of attaching a new flow direction adjusting fin 25 each time molding is performed.

  Next, Embodiment 3 of the present invention will be described with reference to FIGS. However, substantially the same parts as those in the first embodiment are denoted by the same reference numerals, and the description will be simplified. The parts different from the first embodiment will be mainly described.

  As shown in FIGS. 9 and 10, in the third embodiment, a flow direction adjusting fin 26 (flow direction adjusting means) is provided on the lower edge portion of the middle mold 20 of the mold 17. The flow direction adjusting fin 26 has a tip side portion protruding into the cavity in a state where the root side portion is pierced by a pin 27 or the like fixed to the lower edge portion of the middle mold 20 and temporarily fixed. Yes. The flow direction adjusting fin 26 is formed of a material that is easily fixed to the cushion material 11 (for example, the same nonwoven fabric as felt and the like of the molding auxiliary material 15 of the first embodiment), and the flow direction adjusting fin 26 is released when the cushion material 11 is released. 26 is extracted integrally with the cushion material 11 from the mold 17 (medium mold 20). This flow direction adjusting fin 26 also has a length in the cavity channel width direction of 20 to 95 of the cavity channel width when it is in a free state (indicated by a two-dot chain line in FIG. 10) that is not pushed by the foamable raw material. % Is set.

  Even in the case of the third embodiment described above, the foamable raw material can be flowed and filled into the concave portion 24a (difficult inflow portion) by the flow direction adjusting fin 26 provided in the molding die 17 (medium die 20). It is possible to prevent or reduce the occurrence of air accumulation in the cavity easily and at low cost, and to prevent or reduce the occurrence of a lack of thickness due to the air accumulation in the cushion material 11 at low cost. Can do.

  In the third embodiment, the flow direction adjusting fin 26 is formed of a material that is easily fixed to the cushion material 11, and the flow direction adjusting fin 26 is moved from the mold 17 to the cushion material 11 when the cushion material 11 is released. Since it is made to be taken out integrally, the flow direction adjusting fin 26 can be integrated with the cushion material 11 and can function as a reinforcing material for the cushion material 11 or the like.

  In Examples 2 and 3, the flow direction adjusting fins 25 and 26 are provided at the edge of the middle mold 20 of the mold 17. Accordingly, the position where the flow direction adjusting fin 16 is formed may be changed as appropriate. For example, the flow direction adjusting fin may be provided at the center of the middle mold 20. Further, the flow direction adjusting fins 25 and 26 may be provided on the upper mold 18 and the lower mold 19 of the mold 17.

  Further, in each of the above Examples 1 to 3, the length of the flow direction adjusting fins 16, 25, 26 in the cavity flow path width direction is set to 20 to 95% of the cavity flow path width, but is not limited thereto. Depending on the shape and strength of the flow direction adjusting fins 16, 25, and 26, the deformation state when the foamable raw material flows, the length of the flow direction adjusting fins 16, 25, and 26 in the cavity channel width direction is May be shorter than 20%, or may be longer than 95% of the cavity flow path width.

  The shape of the flow direction adjusting means for adjusting the flow direction of the foamable raw material is not limited to a fin shape, and may be appropriately changed.

  Further, in each of the first to third embodiments, the flow direction adjusting means is arranged on the upstream side of the difficult inflow portion (concave portion 24a) in which the foamable raw material hardly flows, but the flow direction adjusting means is difficult. It arrange | positions in the downstream of an inflow part (concave part 24a), and the flow direction of a part of foamable raw material flows backward in the direction of a difficult inflow part (concave part 24a) in the downstream of a difficult inflow part (concave part 24a). You may make it adjust so.

  Furthermore, although the present invention can produce a foamed molded product that does not generate air stagnation when implemented alone, it may be implemented in combination with other means.

  In addition, the application range of the present invention is not limited to a cushion material for an automobile seat back, and can be widely applied to foam molded products that may cause air accumulation during molding. Further, the present invention is not limited to polyurethane foam molded products, and can be widely applied to foam molded products formed by foaming and flowing a liquid foamable raw material, such as phenol resin and urea resin foam molded products. Furthermore, the present invention can also be applied to a method in which a gas such as carbon dioxide is forcibly injected as fine bubbles into an injection raw material and foamed.

It is the perspective view seen from the back side of the cushioning material in Example 1 of the present invention. It is AA sectional drawing of FIG. It is a perspective view which shows the state at the time of opening of the shaping | molding die of Example 1. FIG. It is BB sectional drawing of FIG. It is CC sectional drawing of FIG. FIG. 3 is an enlarged cross-sectional view of a peripheral portion of a flow direction adjusting fin in the mold of Example 1. It is a perspective view of the middle model of Example 2, and a flow direction adjustment fin. 6 is a partially enlarged cross-sectional view of a molding die of Example 2. FIG. It is a perspective view of the middle model of Example 3, and a flow direction adjustment fin. 6 is a partial enlarged cross-sectional view of a mold according to Example 3. FIG.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 11 ... Cushion material (foam molded product), 12 ... Center part, 13 ... Side part, 13a ... Convex part, 15 ... Molding auxiliary material, 16 ... Flow direction adjustment fin (flow direction adjustment means), 17 ... Mold DESCRIPTION OF SYMBOLS 18 ... Upper mold | type, 19 ... Lower mold | type, 20 ... Medium mold | type, 22 ... Center cavity, 23 ... Side cavity, 24 ... Cavity, 24a ... Concave part (difficult flow part), 25 ... Flow direction adjustment fin (flow direction adjustment means) , 26 ... Flow direction adjusting fin (flow direction adjusting means)

Claims (17)

With the molding auxiliary material set in the cavity of the molding die, the foamable raw material injected into the cavity is foamed and fluidized to fill the foamable raw material into the cavity. In the method of manufacturing a foam molded product for molding an integrated foam molded product,
A flow direction adjusting means for adjusting the flow direction of the foamable raw material is provided at a position corresponding to or near a portion of the molding auxiliary material corresponding to a portion where air accumulation is likely to occur in the cavity. The flow direction of the foamable raw material is reduced or prevented by the flow direction adjusting means when the molding auxiliary material is set in the cavity to foam and flow the foamable raw material. A method for producing a foam-molded product, characterized in that the foamed molded product is adjusted in a direction to perform.   The said flow direction adjustment means is formed using the edge of the said molding auxiliary material, The manufacturing method of the foaming molded product of Claim 1 characterized by the above-mentioned. The mold is composed of an upper mold, a lower mold, and a middle mold disposed between the two molds,
The method for producing a foam molded product according to claim 1, wherein the molding auxiliary material is attached to the middle mold. In the method for producing a foam molded product, the liquid foamable raw material injected into the mold cavity is foamed and fluidized to fill the foamable raw material into the cavity and mold the foam molded product.
A flow direction adjusting means for adjusting the flow direction of the foamable raw material is provided at a position corresponding to or near a portion of the mold that is likely to cause air accumulation in the cavity. When the foamable raw material is foamed and fluidized, the flow direction of the foamable raw material is adjusted by the flow direction adjusting means in a direction to reduce or prevent the occurrence of air stagnation. Manufacturing method. The mold is composed of an upper mold, a lower mold, and a middle mold disposed between the two molds,
The method for manufacturing a foam molded article according to claim 4, wherein the flow direction adjusting means is provided in the middle mold so as to protrude into the cavity.   The flow direction adjusting means is disposed on the upstream side of the difficult inflow portion where the foamable raw material is difficult to flow in the cavity, and the flow direction of the foamable raw material is set on the upstream side of the difficult inflow portion. 6. The method for producing a foam-molded product according to claim 1, wherein the foam-molded product is adjusted so as to be directed toward the part.   The flow direction adjusting means is disposed on the downstream side of the difficult inflow portion where the foamable raw material is difficult to flow in the cavity, and the flow direction of a part of the foamable raw material is set on the downstream side of the difficult inflow portion. 6. The method for producing a foam-molded article according to claim 1, wherein the foamed molded article is adjusted so as to flow backward in the direction of the difficult inflow portion.   The said flow direction adjustment means is formed in the length extended in the area | region of 20 to 95% with respect to the flow path width of the said cavity, The Claim 1 thru | or 7 characterized by the above-mentioned. A method for producing a foam molded article. With the molding auxiliary material set in the cavity of the molding die, the foamable raw material injected into the cavity is foamed and fluidized to fill the foamable raw material into the cavity. In a foam molding product manufacturing apparatus for molding an integrated foam molding product,
In the molding auxiliary material, the flow direction of the foamable raw material is reduced in the flow direction of the foamable raw material at a position corresponding to or near a portion where air accumulation is expected to occur in the cavity. An apparatus for manufacturing a foam-molded article, characterized in that a flow direction adjusting means for adjusting in a preventing direction is provided.   The said flow direction adjustment means is formed using the edge part of the said molding auxiliary material, The manufacturing apparatus of the foaming molded article of Claim 9 characterized by the above-mentioned. In a foam molded product manufacturing apparatus for forming a foam molded product by filling the foamable raw material into the cavity by foaming and flowing a liquid foamable raw material injected into the cavity of the mold,
The flow direction of the foamable raw material is reduced or prevented at the position corresponding to or near the portion of the mold that is likely to generate air accumulation in the cavity. An apparatus for producing a foam-molded article, characterized in that a flow direction adjusting means for adjusting in a direction to perform is provided.   12. The foam molded product manufacturing apparatus according to claim 11, wherein the flow direction adjusting means is formed of a releasable material that is difficult to adhere to the foam molded product, and is provided in the mold.   The flow direction adjusting means is formed of a material that is easily fixed to a foam molded product, and is provided in the molding die so as to be taken out integrally with the foam molded product from the mold when releasing. Item 12. A foamed article manufacturing apparatus according to Item 11. When the foamable raw material injected into the cavity of the mold is foamed and fluidized to fill the foamable raw material into the cavity and mold the foamed molded product, it is set in the mold in advance. In the molding auxiliary material integrated with the foam molded article,
In the molding auxiliary material, the flow direction of the foamable raw material is reduced in the flow direction of the foamable raw material at a position corresponding to or near a portion where air accumulation is expected to occur in the cavity. A molding auxiliary material for foam-molded products, characterized in that a flow direction adjusting means for adjusting in a preventing direction is provided.   15. The molding auxiliary material for a foam molded product according to claim 14, wherein the flow direction adjusting means is formed by using an edge portion of the molding auxiliary material.   The formed auxiliary material is formed by sewing cloth-like members cut into a predetermined shape, and a part in which a plurality of edges of the cloth-like member are overlapped or a part in which the edges of the cloth-like member are folded and overlapped The molding auxiliary material for foam-molded products according to claim 15, wherein the flow direction adjusting means is formed by using.   The molding auxiliary material is formed of a material that has innumerable fine voids inside to prevent permeation of the foamable raw material in the thickness direction and allow air to flow in the surface direction. The molding auxiliary material of the foaming molded article in any one of Claims 14 thru | or 16.

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