JP2005211298A - Manufacturing method for surface integrated foam molding seat - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method for a surface integrated foam molding seat efficiently foam-molding a back pad of resin foam integrally with a seat surface by focusing attention on a time required for assembling a core mold to the seat surface. <P>SOLUTION: This manufacturing method includes to provide through-holes 41 and 42 for assembling support cylinders of headrest stays in a top part surface 40b; provide a seat surface 4 having temporary fixing clothes 43 and 44 at the end of a seat part face 40a; provide the core mold 3 provided with stays 31 and 32 projecting outward from an upper frame side 30c, stays 33 and 34 projecting outward from a lower frame side 30d and locking pins 35 and 36; insert the stays 31 and 32 of the upper frame side 30c into the through-hole 41 of the top part face 40b; hook the temporary fixing clothes 43 and 44 of the seat part face to the locking pins 35 and 36 of the lower frame side 30d to retain the seat surface to the core mold 3; and assemble the seat surface 4 in the mold of a drag by the core mold 3. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention comprises a back cover bag-like sheet skin, and the back pad is foam-molded integrally with the sheet skin by foamed resin, so that the skin-integrated foam-molded sheet applied to mold a seat back of an automobile seat It relates to a manufacturing method.

  Conventionally, when molding automobile seats, the back cover bag-shaped sheet skin is assembled in the lower mold according to the shape, then the core mold is assembled inside the seat skin, and the upper mold is molded into the lower mold. After tightening, it has been proposed to inject a foamed resin into the inside of the sheet skin from the upper mold side and foam-mold the back pad integrally with the sheet skin from the foamed resin (Patent Document 1).

In the automobile seat manufacturing method, since the core is assembled to the inside of the seat skin after the seat skin is matched to the mold surface of the lower mold, the assembly of the core mold is performed rather than the assembly of the seat skin to the lower mold. From the standpoint of efficiently using a single mold, productivity is lacking because it takes time to attach.
Reality 5-44101

  The main problem to be solved by the present invention is to pay attention to the time required for the assembly of the core mold to the sheet skin, and to make the back pad integrated foam molded sheet that can be efficiently foam-molded integrally with the sheet skin by the foam resin. It is to provide a manufacturing method.

  Another object of the present invention is to provide a method for producing a skin-integrated foam-molded sheet that allows a sheet skin to be easily and reliably assembled into a core mold.

  Another object of the present invention is to provide a method for producing a skin-integrated foam-molded sheet in which the sheet skin can be accurately assembled into a lower mold with a core mold.

According to a first aspect of the present invention, there is provided a method of manufacturing a skin-integrated foam-molded sheet having a back bag shape in which a through hole for assembling a support tube of a headrest stay is provided on a top surface and a temporary fixing cloth is provided on a terminal of a seat surface. A core type having a seat skin and having a substantially quadrilateral main body frame, and having a support shaft protruding outward from the upper frame side, a support shaft protruding outward from the lower frame side, and a stop pin. Prepared,
Insert the spindle of the upper frame side into the through hole in the top surface, hook the temporary fixing cloth of the seat surface to the fixing pin on the lower frame side, assemble the main body frame inside the seat cover and insert the seat cover into the core After holding the mold, the seat cover is assembled into the lower mold in the core mold, the upper mold is clamped to the lower mold, and the back pad is seated with foamed resin that is injected into the seat cover from the upper mold side. It is characterized by being foam-molded integrally with the skin.

  The manufacturing method of the skin-integrated foam-molded sheet according to claim 2 of the present invention is characterized in that the core mold is installed on a support base with a support shaft on the lower frame side, and the sheet skin is assembled to the core mold. .

  According to a third aspect of the present invention, there is provided a method for manufacturing a skin-integrated foam-molded sheet, wherein a main body frame is positioned by fitting a support shaft of an upper frame side and a support shaft of a lower frame side to a mating surface of a lower mold, The epidermis is assembled into a lower mold with a core mold.

  In the manufacturing method of the skin-integrated foam-molded sheet according to claim 1 of the present invention, since the sheet skin is pre-assembled into the core mold and the core mold is assembled into the lower mold, the sheet skin is quickly assembled together with the core mold. It is assembled in the lower mold. In addition, because the seat cover can be easily assembled to the inner insert with the lower frame side retaining pin that holds the temporary fastening cloth on the seat surface, one molding die can be used efficiently to produce a foam integrated foam sheet. Increases sex.

  In the manufacturing method of the skin-integrated foam-molded sheet according to claim 2 of the present invention, since the core mold is installed on the support base with the support shaft on the lower frame side, the sheet skin is assembled to the core mold. The child mold can be quickly assembled to the seat skin.

  In the manufacturing method of the skin-integrated foam-molded sheet according to claim 3 of the present invention, the main body frame is positioned by the support shaft of the upper frame side and the support shaft of the lower frame side so that the sheet skin is a core mold and a lower mold. Because it is assembled inside, the sheet skin can be accurately assembled into the lower mold with a core type.

  FIG. 1 mainly shows a mold used for manufacturing a seat back of an automobile seat as a skin-integrated foam molded product. This molding die includes a lower die 1 and an upper die 2 as a die body, and includes a core die 3 that is inserted into upper and lower, 1 and 2 die, and a sheet skin 4 is placed in the die of the lower die 1 with the core die 3. In addition, the upper mold 2 is clamped to the lower mold 1 and foamed resin is injected into the seat skin 4 from the upper mold 1 so that the back pad 5 is foam-molded integrally with the seat skin 4. .

  The lower mold 1 includes a lower mold body 10 that shapes the seat back portion of the seat back, a first side split mold 11 that shapes the back and back portions of the seat back in a flat shape, and a side surface portion of the seat back. The second side split mold 12 is assembled. The upper die 2 is formed with a convex portion 21 that enters the die of the lower die 1 from the die matching portion 20.

  In the configuration of the lower mold 1, the first side split mold 11 is connected to the second side split mold 12 by a hinge 13a so that the mold can be opened or closed. The second side split mold 12 is connected to both ends of the lower mold main body 10 by hinges 13b so that the mold can be opened or closed.

  The first side split mold 11 has a flat mold surface 11a facing the back and back surfaces of the seat skin 4, and the inner end surface 11b is an upward slope and is formed to face the base end surface 21a of the convex portion 21. Has been. The middle insert 3 has a parting projection 3a facing the mold surface 11a of the side split mold 11, and the inner end surface 3b is an inclined slope and is formed so as to face the projecting end surface 21b of the convex mold portion 21. Yes.

  From the mold structure, the first side split molds 11 are pressed by the upper mold 2, and the back and back terminals of the seat cover 4 are cut off from the mold plane 11 a of the side split mold 11 and the protrusion 3 a of the inner insert 3. It is configured to be shaped. In this mold, when using a sheet skin laminated with a foam slab of 3 to 4 mm, a clearance of about 2.5 to 3 mm is maintained between the mold plane 11 a of the side split mold 11 and the protrusion 3 a of the inner insert 3. Good.

  As shown in FIG. 2, the core mold 3 includes left and right side frame sides 30a, 30b, an upper frame side 30c extending between the upper portions of the side frame sides 30a, 30b, and a lower portion extending between the lower portions of the side frame sides 30a, 30b. The main body frame 30 is formed to have a substantially quadrilateral shape from the frame side 30d, and the lower frame side 30d is continuous with the left and right side frame sides 30a, 30b and the overhang sides 30e, 30f. As shown in FIG. 3 (only one side is shown), the extended side 30e is formed so as to protrude forward from the lower side of the side frame side 30a.

  The upper frame side 30c is provided with stepped bases 31a and 32a having square bar-shaped support shafts 31 and 32 so that the upper frame side 30c protrudes above the reinforcing portions 31b and 32b from the bulge to the front side of the upper frame side 30c. Two are provided apart. On the lower frame side 30d, two round pipe-shaped support shafts 33, 34 are provided at an interval so as to protrude downward, and needle-like stop pins 35, 36 are provided outside the support shafts 33, 34. Two are provided so as to protrude obliquely downward.

  In the configuration, the core mold 3 is formed so as to substantially correspond to the overall shape of the seat back frame except for the support shafts 33 and 34 and the retaining pins 35 and 36 on the lower frame side 30d. The lower frame side 30d is provided with a receiving groove 37 having a downward slope that once receives the foamed resin injected from the nozzle through the insertion hole of the upper mold 2 and flows into the inside of the sheet skin 4. The inlet of the foamed resin is provided in the center when the sheet shape is symmetrical, and is shifted so that the foamed resin flows evenly when it is not symmetrical.

  As shown in FIG. 4, the seat skin 4 is formed by stitching together a seat surface portion 40a, a top surface portion 40b, left and right side surface portions 40c, 40d, and a back back portion 40e of a sheet material obtained by laminating a skin material, a urethane slab, and a backing material. It is formed in a three-dimensional shape like a back bag. Through holes 41 and 42 through which the support shafts 31 and 32 of the upper frame side 30c are inserted are provided in the top surface portion 40b of the seat cover 4 so that a support cylinder (not shown) of the headrest stay can be assembled. In addition, belt-like temporary fixing cloths 43 and 44 are sewn separately on the left and right sides of the end of the seat surface portion 40a.

  In manufacturing the seat back from the skin integral molding, first, the seat skin 4 is assembled to the core mold 3 as shown in FIG. The seat skin 4 can be assembled in a state where the core mold 3 is placed on the set base 6 because the support shafts 33 and 34 of the lower frame side 30d are fitted to the stand posts 60 and 61.

  The seat skin 4 is inserted into the through holes 41 and 42 of the top surface portion 40b until the length of the stepped base portions 31a and 32a does not protrude to the outside, and the seat surface portion 40a is temporarily fixed. The cloths 43 and 44 are wound backward from the lower side of the lower frame side 30d and locked by the locking pins 35 and 36, and the main body frame 30 is inserted into the core mold 3 so that the whole is assembled to the core mold 3. In this assembled state, the top surface portion 40b is positioned by the support shafts 33 and 34 of the lower frame side 30d, the end of the seat surface portion 40a is positioned by the lower frame side 30d, and the inner peripheral edge of the back back portion 40 is positioned by the projecting portion 3a for parting. Retained.

  After the sheet skin 4 is assembled to the core mold 3, the sheet skin 4 is then assembled into the lower mold 1 by the core mold 3 as shown in FIG. At this time, the core mold 3 fits the support shafts 31 and 32 of the upper frame side 30c with the receiving grooves 14 and 15 provided on the mating surface of the lower mold 1, and the support shafts 33 and 34 of the lower frame side 30d. By fitting with receiving grooves 16, 17 provided on the mating surface of the lower mold 1, the whole is positioned and assembled into the mold of the lower mold 1.

  After the seat skin 4 is assembled into the lower mold 1 with the core mold 3, an operator matches the shape of the seat surface portion 40 a on the inner side of the back cover portion of the seat skin 4 with the mold surface of the lower mold 1. The side split mold 11 is placed on the back and back portions 40d of the seat skin 4 from the left and right so as to face the projection 3a for parting out the mold surface, and vacuum drawing is performed so that the seat skin 4 is securely set to the groove on the mold surface. To do. Next, the upper mold 2 is clamped to the lower mold 1 and the evacuation of the sheet skin 4 is stopped, and foamed resin is injected from the upper mold 1 into the sheet skin 4 so that the back pad 5 is attached to the sheet skin 4. What is necessary is just to foam-mold integrally (refer FIG. 1).

  In this method of manufacturing a skin-integrated foam-molded sheet, the sheet skin 4 is assembled to the core mold 3 prior to assembly in the mold of the lower mold 1. It can be quickly assembled after positioning. In addition, during the process of integrally molding the skin with the molding die, the next sheet skin can be assembled and prepared in a separate core die, so that one molding die can be used efficiently, increasing the productivity of the skin integral foam molding sheet. It is done.

It is sectional drawing which shows the shaping | molding die used with the manufacturing method which concerns on this invention in the shaping | molding process of a skin integrated foam molding sheet | seat. It is a rear view which shows the core type | mold with which the shaping | molding die of FIG. 1 is equipped. It is sectional drawing which shows the core type | mold of FIG. 2 by the AA line. It is a rear view which shows the sheet | seat outer skin assembled | attached to the shaping | molding die of FIG. FIG. 5 is a rear view showing the seat cover of FIG. 4 assembled in a core shape. FIG. 6 is a plan view showing the seat cover of FIG. 5 assembled in a lower mold.

Explanation of symbols

3 Core type 30 Core type main body frame 30c Core type upper frame side 30d Core type lower frame side 31, 32 Upper frame side support shaft 33, 34 Lower frame side support shaft 35, 36 Locking pin 4 Seat surface 40a Seat surface 40b Seat surface top 41, 42 Through hole 43, 44 Temporary fixing cloth

Claims (3)

In the manufacturing method of the skin-integrated foam-molded sheet in which the sheet skin is assembled in the upper and lower molds, the foam resin is injected into the sheet skin from the upper mold side, and the back pad is foam-molded integrally with the sheet skin.
The headrest stay has a through hole for assembling the support tube on the top surface, and a back cover bag-like seat cover with a temporary fixing cloth at the end of the seat surface. A core type provided with a support shaft protruding outward from the side, a support shaft protruding outward from the lower frame side, and a stop pin,
Insert the spindle of the upper frame side into the through hole in the top surface, hook the temporary fixing cloth of the seat surface to the fixing pin on the lower frame side, assemble the main body frame inside the seat cover and insert the seat cover into the core After holding the mold, the seat cover is assembled into the lower mold with the core mold, the upper mold is clamped to the lower mold, and the back pad is seated with foam resin injected into the seat cover from the upper mold side. A method for producing a skin-integrated foam-molded sheet, wherein foam-molding is performed integrally with a skin.   2. The method for producing a skin-integrated foam-molded sheet according to claim 1, wherein the core mold is installed on a support stand with a support shaft on the lower frame side, and the sheet skin is assembled to the core mold. The upper frame side support shaft and lower frame side support shaft were fitted to the mating surface of the lower mold to position the main frame, and the seat cover was assembled in the lower mold with a core mold. The manufacturing method of the skin-integrated foam-molded sheet according to claim 1, wherein

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