JP2006212855A - Mold and manufacturing method of foamed molded product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a mold capable of preventing the adhesion of a foamable resin raw material to a fastening surface even in a case that a fastener is projected from a fastener support member when a foamed molded product having the fastener integrally molded thereon is manufactured. <P>SOLUTION: The mold used for manufacturing the foamed molded product having the fastener 1 integrally molded thereon is equipped with the rail arranging surface 33, which is provided to the base 34 of the cavity of the mold and has a rail 2 for supporting the fastener 1 arranged thereto, and the depressed part 36 formed in close vicinity to the outside in the longitudinal direction L2 of the rail 2 arranged to the rail arranging surface 33. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a molding die used for manufacturing a foam molded product in which a fastener such as a seat pad for a vehicle is integrally molded, and a method for manufacturing a foam molded product in which a fastener is integrally molded.

  Conventionally, a cushion material in which a skin material is assembled to urethane foam (an example of a foam molded product) is used as a vehicle seat or an interior product of a door. Such a skin material is generally detachably assembled by a fastener such as a surface fastener integrally formed with urethane foam.

  A method for manufacturing a urethane foam in which fasteners are integrally formed will be briefly described as follows. First, as shown in FIG. 7, the fastener 1 is disposed in a molding die 3 composed of a lower die 31 and an upper die 32. The fastener 1 is mounted on a rail 2 (fastener support member) having a concave cross-sectional shape so as to cover the fastening surface, and is fixed to the cavity bottom surface 34. The rail 2 is arranged on a rail arrangement surface 33 provided on the convex portion 35 of the cavity bottom surface 34.

  Next, as shown in FIG. 8, a required amount of liquid foamed resin raw material 37 is supplied into the molding die 3 and clamping is performed. When the foamed resin material 37 starts to react, gas starts to be generated, and the foamed resin material 37 is emulsified to become a gas-liquid heterogeneous system. When the reaction further proceeds, the foamed resin raw material 37 becomes a gel-like gas-solid heterogeneous system having poor fluidity, and eventually expands the gas into a foam (foam). In such a foaming process, the foamed resin raw material 37 expands and fills the molding die 3 as shown in FIGS. At this time, since the fastening surface of the fastener 1 is covered with the rail 2, adhesion of the foamed resin raw material 37 to the fastening surface is prevented, and assembling with the skin material is ensured. After the reaction of the foamed resin raw material 37 is completed, the upper mold 32 is removed from the lower mold 31, and the molded product is demolded. Such a method for producing a foam-molded product is disclosed, for example, in Patent Document 1 below.

Here, for example, as shown in FIG. 12 and FIG. 13, when the fastener 1 protrudes from the rail 2 and is mounted, there are the following problems in the foaming process. That is, when the foamed resin raw material expands and reaches the height of the fastening surface 14 of the fastener 1, a force that pushes the protruding portion of the fastener 1 upwards acts to cause the fastener 1 to float from the rail 2. Usually, the viscosity of the foamed resin raw material at this stage is relatively low, so that there is a problem that it enters between the fastener 1 and the rail 2 and adheres to the fastening surface 14. There are several reasons why a properly mounted fastener may protrude from the rail. For example, a fastener having a length exceeding the allowable range of the rail may be used.
JP 2003-170444 A JP 2003-320536 A

  The present invention has been made in view of the above circumstances, and the problem is that when a foam molded product in which a fastener is integrally formed is manufactured, even if the fastener protrudes from the fastener support member, the fastening surface is provided. It is to provide a molding die and a method for producing a foamed molded product that can prevent the foamed resin material from adhering to the surface.

  The above object can be achieved by the present invention as described below. That is, the molding die according to the present invention is a molding die used for manufacturing a foam molded product in which fasteners are integrally molded, and is provided on the cavity bottom surface of the molding die, and is a fastener support for supporting the fastener. A support member disposition surface on which the member is disposed, and a recess formed close to the outer side in the longitudinal direction of the fastener support member disposed on the support member disposition surface.

  According to the molding die according to the present invention, the recessed portion is formed in the vicinity of the outer side in the longitudinal direction of the fastener support member disposed on the support member mounting surface, so that the outer side in the longitudinal direction of the fastener support member is formed. The foamed resin raw material can be dropped into the recessed portion. Thereby, when the foamed resin raw material on the outer side in the longitudinal direction of the fastener support member expands and reaches the height of the fastening surface of the fastener, the reaction of the foamed resin raw material proceeds as compared with the conventional case. Therefore, when the fastener protrudes in the longitudinal direction from the fastener support member, even if the foamed resin raw material pushes up the protruding portion and lifts the fastener from the fastener support member, the foamed resin raw material has a relatively high viscosity. Therefore, it is difficult to enter between the fastener and the fastener support member, and adhesion of the foamed resin material to the fastening surface can be effectively prevented.

  The foam molded product manufacturing method according to the present invention is a method for manufacturing a foam molded product in which a fastener is integrally molded. A fastener support member for supporting the fastener is recessed on the outer side in the longitudinal direction of the fastener support member. The disposing step of disposing the support member disposed on the bottom surface of the cavity of the molding die so that the portions are located close to each other, and before or after the disposing step, A mounting step of mounting the fastener on the fastener support member; and a foam molding step of supplying a foamed resin raw material into the molding die for foam curing.

  According to the method for manufacturing a foam molded product according to the present invention, the fastener support member is disposed so that the recessed portion is located close to the outer side in the longitudinal direction. Therefore, in the foam molding step, the outer side in the longitudinal direction of the fastener support member. The foamed resin material can be dropped into the recessed portion. Thereby, when the foamed resin raw material on the outer side in the longitudinal direction of the fastener support member expands and reaches the height of the fastening surface of the fastener, the reaction of the foamed resin raw material proceeds as compared with the conventional case. Therefore, when the fastener protrudes in the longitudinal direction from the fastener support member, even if the foamed resin raw material pushes up the protruding portion and lifts the fastener from the fastener support member, the foamed resin raw material has a relatively high viscosity. Therefore, it is difficult to enter between the fastener and the fastener support member, and adhesion of the foamed resin material to the fastening surface can be effectively prevented.

  In the above, a positioning jig is provided at one end in the longitudinal direction of the fastener support member, and a locking portion that can be locked to the positioning jig is formed at both ends in the longitudinal direction of the fastener. Those are preferred.

  FIG. 14 is a perspective view showing a conventional fastener and a fastener supporting member. Components that are the same as those of the members described in the embodiments of the present invention to be described later are denoted by the same reference numerals. A positioning pin 23 (corresponding to the positioning jig) is provided at the end E3 in the longitudinal direction L2 of the rail 2 (fastener support member), and the end in the longitudinal direction L1 of the fastener is correspondingly provided. A locking portion 17 that can be locked to the positioning pin 23 is formed at E1. As a result, when attaching the fastener 1 to the rail 2, the operator first positions the pin 17 by engaging the locking portion 17 with the positioning pin 23, and pushes the fastener 1 toward the rail 2 along the longitudinal direction L2 from this state. Thus, the fastener 1 can be easily and reliably mounted. The rail 2 having such positioning pins 23 is disclosed in, for example, the above-mentioned Patent Document 2.

  On the other hand, the manufacturing method of the foam-molded article which concerns on this invention uses the fastener by which the latching | locking part was formed in the both ends of a longitudinal direction. As a result, when attaching the fastener to the fastener support member, the operator does not need to check which end of the fastener is provided with the engaging portion, and can easily and easily attach the fastener. it can. At this time, since the locking portions are formed at both ends, the fastener becomes longer than the conventional fastener, so the fastener protrudes in the longitudinal direction from the fastener support member (see FIG. 2). Since the recessed portion is located close to the outer side in the longitudinal direction of the fastener support member, the above-described effects can be obtained and adhesion of the foamed resin material to the fastening surface can be effectively prevented.

  In the above, the fastener support member includes a recess into which the fastener is fitted, and a side wall portion extending in the height direction from both sides in the width direction of the recess, and R machining is performed on a longitudinal outer corner portion of the side wall portion. Those applied are preferred.

  According to the said structure, when removing a molded article after a foam molding process, mold removal can be performed smoothly, without a molded article catching on the longitudinal direction outer side corner part of the side wall part with which a fastener support member is equipped.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view showing a fastener and a fastener support member. FIG. 2 is a perspective view of a fastener support member equipped with the fastener. 3 is a cross-sectional view taken along line AA in FIG.

  The fastener 1 has a base 11, a fastening surface 14 formed on one surface of the base 11, and a joint surface 15 formed on the other surface. The base 11 is a long member having a plurality of rectangular parallelepiped segments connected in the longitudinal direction L1 and having appropriate flexibility. As shown in FIG. 3, a plurality of engaging protrusions 12 having a head portion 13 bulging and formed are provided on the fastening surface 14. On the other hand, a plurality of anchors 16 having a T-shaped cross-section are erected on the joining surface 15, thereby ensuring the joining strength between the fastener 1 and urethane foam (an example of a foam molded product).

  Locking portions 17 are formed at both end portions E1 and E2 of the fastener 1 in the longitudinal direction L1. The locking part 17 is formed in a hook shape having a U-shaped side surface. The locking portion 17 of the end portion E1 and the locking portion 17 of the end portion E2 are in a point-symmetrical relationship in plan view, and when mounted on a rail 2 (corresponding to the fastener support member) described later, You may replace the position of the part E1 and the edge part E2.

  The fastener 1 is integrally formed from a resin material by a conventionally known method, and the shape and dimensions thereof are not particularly limited. For example, the segment constituting the base 11 may have a shape other than a rectangular parallelepiped, and the engagement protrusion 12 may be hook-shaped or the head 13 may be hemispherical.

  The rail 2 is a columnar member having a concave cross-sectional shape as shown in FIGS. 1 and 3, and is manufactured from aluminum or an aluminum alloy by extrusion molding or injection molding. The rail 2 includes a recess 21 into which the base 11 of the fastener 1 is fitted, and side wall portions 22 extending in the height direction H from both sides of the recess 21 in the width direction W. The clearance between the base 11 and the side wall portion 22 of the attached fastener 1 is set to be small so that the foamed resin material does not enter the fastening surface 14. Moreover, in this embodiment, the step part 24 which can contact | abut to the fastening surface 14 is formed in the both sides of the recessed part 21, and the penetration | invasion of the foaming resin raw material to the fastening surface 14 is prevented more effectively. As shown in FIGS. 1 and 2, the outer side corner portion 25 in the longitudinal direction of the side wall portion 22 is subjected to R processing of about R10.

  A positioning pin 23 (corresponding to the positioning jig) extending toward the fastener 1 is provided at an end E3 (corresponding to the one end) of the rail 2 in the longitudinal direction L2. A locking portion 17 of the fastener 1 is hooked on the positioning pin 23, whereby the fastener 1 is locked and can be positioned.

  When attaching the fastener 1 to the rail 2, first, as shown in FIG. 4A, the end E1 of the fastener 1 is pushed into the end E3 of the rail 2, and the locking portion 17 is hooked on the positioning pin 23. . At this stage, the fastener 1 is accurately positioned with respect to the rail 2. In addition, since the latching | locking part 17 is formed in the both ends E1 and E2 of the fastener 1, it is not necessary for the operator to confirm which side of the fastener 1 the latching part 17 is formed, Work can be performed efficiently and easily.

  Next, as shown in FIG. 4B, the fastener 1 is pushed into the rail 2 side along the longitudinal direction L2. Specifically, the joining surface 15 of the fastener 1 may be pushed in while tracing with a finger or the like from the end E1 toward the end E2. Since the fastener 1 is positioned in a state of being locked by the positioning pin 23, it is mounted on the rail 2 without being displaced in the longitudinal direction L2. Since the fastener 1 is provided with the locking portions 17 at both ends E1 and E2, the fastener 1 is longer than the conventional fastener and protrudes in the longitudinal direction L2 while being attached to the rail 2.

  Next, the manufacturing method of the urethane foam in which the fastener is integrally formed will be described. FIG. 5 is a side view of the fastener support member disposed on the support member disposition surface. FIG. 6 is a perspective cross-sectional view of a molding die showing a fastener support member disposed on a support member disposition surface. FIGS. 7-10 is sectional drawing of the shaping die which shows the manufacturing process of urethane foam.

  First, a molding die 3 for molding urethane foam is prepared (see FIG. 7). The molding die 3 of the present embodiment includes a lower die 31 and an upper die 32 that covers the open portion of the lower die 31 and is detachably disposed. The bottom surface 34 of the lower mold 31 is provided with a rail disposition surface 33 (corresponding to the support member disposition surface) on which the rail 2 is disposed. In this embodiment, the convex portion of the cavity bottom surface 34 is provided. 35. The rail 2 is arranged on the rail arrangement surface 33 with the lower mold 31 open, and is fixed by a conventionally known method (corresponding to the arrangement step).

  Subsequently, the fastener 1 is mounted on the rail 2 (corresponding to the mounting step). As described above, the operator can easily attach the fastener 1 without confirming on which side of the fastener 1 the locking portion 17 is formed. Further, the attached fastener 1 protrudes from the rail 2 in the longitudinal direction L2. In addition, it is not restricted to what attaches the fastener 1 to the rail 2 arrange | positioned in the molding die 3 like this embodiment, The rail 2 which attached the fastener 1 previously is arrange | positioned in the molding die 3. It doesn't matter.

  In the present invention, as shown in FIGS. 5 and 6, a recessed portion 36 is formed in the vicinity of the outside in the longitudinal direction L <b> 2 of the rail 2 arranged on the rail arrangement surface 33. The depth d of the recessed portion 36 is not particularly limited as long as the effects of the present invention can be obtained. In the present embodiment, the depth d is set to about 10 mm from the rail disposition surface 33, and the bottom surface of the recessed portion 36. Is lower than the cavity bottom surface 34. Further, the area of the recessed portion 36 is not particularly limited, but is preferably an area that can include a portion of the fastener 1 protruding from the rail 2.

  Thereafter, the upper mold 32 is disposed with respect to the lower mold 31, and the liquid foamed resin raw material 37 is supplied into the molding die 3 as shown in FIG. The foamed resin raw material 37 starts the reaction, expands as shown in FIGS. 9 and 10 while increasing the viscosity, and gradually fills the molding die 3 (corresponding to the foam molding step).

  In the above, since the foamed resin raw material 37 is dropped into the recessed portion 36 outside the rail 2 in the longitudinal direction L2, when the foamed resin raw material 37 reaches the height of the fastening surface 14, the reaction proceeds as compared with the conventional case. ing. As a result, even if the foamed resin material 37 pushes up the protruding portion of the fastener 1 and floats from the rail 2, the foamed resin material 37 outside the rail 2 in the longitudinal direction L2 has a relatively high viscosity. And the rail 2 are less likely to enter, and adhesion of the foamed resin material 37 to the fastening surface 14 is prevented. On the other hand, the foamed resin raw material 37 adheres to the joint surface 15 of the fastener 1 and is integrated with the fastener 1. If the area of the recessed portion 36 can include the protruding portion of the fastener 1 as described above, the above-described effects can be more reliably achieved.

  After foaming and curing of the foamed resin material 37 is completed, the upper mold 32 is removed, and the urethane foam is removed from the open portion of the lower mold 31. At this time, since the outer side corner portion 25 in the longitudinal direction of the side wall portion 22 is R-processed, the mold release can be smoothly performed without the urethane foam being caught.

<Another embodiment>
(1) Although the rail 2 has the positioning pin 23 and the fastener 1 has the latching | locking part 17 in the above-mentioned embodiment, this invention is not limited to this. Moreover, the fastener 1 and the rail 2 are not restricted to what extends linearly, You may extend what curves. Further, the rail arrangement surface 33 is not limited to the one provided on the convex portion 35 of the cavity bottom surface 34.

  (2) FIG. 11 is a diagram showing a recessed portion according to another embodiment. The rail mounting surface 33 is provided on the convex portion 35 of the cavity bottom surface 34, and the concave portion 38 is pocket-shaped on the convex portion 35 adjacent to the outside in the longitudinal direction of the rail 2 disposed on the rail mounting surface 33. Is provided. According to such a configuration, when the foamed resin material expands and reaches the height of the convex portion 35, the foamed resin raw material on the outer side in the longitudinal direction of the rail 2 is dropped into the recessed portion 38. As a result, when the foamed resin raw material expands and reaches the height of the fastening surface, the viscosity is higher, and adhesion to the fastening surface 14 is more effectively prevented.

The perspective view which shows a fastener and a fastener support member Perspective view of a fastener support member fitted with a fastener AA sectional view in FIG. The perspective view which shows a mode that a fastener is mounted | worn with a fastener support member Side view of fastener support member disposed on support member disposition surface A perspective sectional view of a molding die showing a fastener support member arranged on a support member arrangement surface Cross section of the mold showing the manufacturing process of urethane foam Cross section of the mold showing the manufacturing process of urethane foam Cross section of the mold showing the manufacturing process of urethane foam Cross section of the mold showing the manufacturing process of urethane foam The figure which shows the recessed part which concerns on another form Side view of a fastener support member disposed in a molding die Perspective cross-sectional view of a molding die showing a support member arrangement surface A perspective view showing a conventional fastener and a fastener support member

Explanation of symbols

1 Fastener 2 Rail (Fastener support member)
3 Molding die 11 Base 12 Engaging projection 14 Fastening surface 15 Joining surface 17 Locking portion 21 Recess 22 Side wall portion 23 Positioning pin (positioning jig)
25 Longitudinal outer corner 31 Lower mold 32 Upper mold 33 Rail arrangement surface (support member arrangement surface)
34 Cavity bottom 35 Convex part 36 Concave part 37 Foamed resin raw material 38 Concave part d Depth of concave part E1 Fastener end E2 Fastener end E3 End part (one end part) of rail (fastener support member)
H Height direction L1 Fastener longitudinal direction L2 Rail (fastener support member) longitudinal direction W Rail (fastener support member) width direction

Claims (4)

In a molding die used for manufacturing a foam molded product in which fasteners are integrally molded,
A support member disposition surface provided on a bottom surface of the cavity of the molding die, on which a fastener support member for supporting the fastener is disposed;
A molding die comprising: a recessed portion formed adjacent to an outer side in a longitudinal direction of the fastener support member disposed on the support member disposition surface. In the manufacturing method of the foam molded product in which the fastener is integrally formed,
A fastener support member for supporting the fastener is disposed on a support member disposition surface provided on the bottom surface of the cavity of the molding die so that the recessed portion is located close to the longitudinal outer side of the fastener support member. An arranging step to perform,
A mounting step of mounting the fastener on the fastener support member before or after the positioning step;
A foam molding step of supplying a foamed resin raw material into the molding die and foaming and curing the foamed resin raw material.   3. A positioning jig is provided at one end in the longitudinal direction of the fastener support member, and a locking portion that can be locked to the positioning jig is formed at both ends in the longitudinal direction of the fastener. Manufacturing method of foam molded article.   The fastener support member includes a recess into which the fastener is fitted, and a side wall portion extending in the height direction from both sides in the width direction of the recess, and R processing is applied to a longitudinal outer corner of the side wall portion. The manufacturing method of the foaming molded article of Claim 2 or 3.

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