JP2008126633A - Manufacturing method of foamed resin molded product - Google Patents

Manufacturing method of foamed resin molded product Download PDF

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JP2008126633A
JP2008126633A JP2006317263A JP2006317263A JP2008126633A JP 2008126633 A JP2008126633 A JP 2008126633A JP 2006317263 A JP2006317263 A JP 2006317263A JP 2006317263 A JP2006317263 A JP 2006317263A JP 2008126633 A JP2008126633 A JP 2008126633A
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foamed resin
magnetic
molded product
resin molded
mold
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Hisamitsu Shinohara
寿充 篠原
Yutaka Hirata
豊 平田
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Bridgestone Corp
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Bridgestone Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a foamed resin molded product capable of holding a subsidiary material such as a fibrous material or the like to the inner surface of a mold by an easy and inexpensive technique and not lowering the characteristics of the fibrous material. <P>SOLUTION: The subsidiary material 4 comprises a laminate composed of layers 4a and 4b, and magnetic fibers 5 are interposed between the layers 4a and 4b in the regions facing magnets 3 and magnetically attracted by the magnets 3 to hold the sheetlike subsidiary material 4 to the inner surface of an upper mold 1 as a whole in a close contact state. After a urethane raw liquid is supplied in a lower mold 2, the upper mold 1 having the subsidiary material 4 magnetically attracted on its inner surface is mounted on and clamped to the lower mold 2 to heat and foam urethane. After foaming, the mold is opened to demold the foamed resin molded product. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

本発明は自動車のシートパッドを成形する方法等に適用される発泡樹脂成形品の製造方法に係り、特に繊維系素材などの副資材を一体に成形する発泡樹脂成形品の製造方法に関する。   The present invention relates to a method for manufacturing a foamed resin molded product applied to a method for molding a seat pad of an automobile, and more particularly to a method for manufacturing a foamed resin molded product in which auxiliary materials such as a fiber-based material are integrally molded.

自動車用シートパッドとして、繊維系素材などの副資材をポリウレタンフォームなどの樹脂発泡体と一体化させたものがある。このような繊維系素材を樹脂発泡体と一体化させる成形方法として、特開2001−252930号には、ポリエステル繊維やアクリル繊維よりなる繊維系素材に磁性を付与し、金型に設けたマグネットによって繊維系素材を金型内面に保持させておいて発泡成形する方法が記載されている。   As an automobile seat pad, there is one in which a subsidiary material such as a fiber material is integrated with a resin foam such as polyurethane foam. As a molding method for integrating such a fiber material with a resin foam, JP-A-2001-252930 gives magnetism to a fiber material made of polyester fiber or acrylic fiber and uses a magnet provided in a mold. A method is described in which a fiber material is held on the inner surface of a mold and foam-molded.

同号公報には、繊維系素材に磁性を付与する方法として、繊維系素材のバインダー中に鉄粉等の磁性粉を混入させる方法や、磁性粉の層を繊維系素材と層と接着一体化する方法、繊維系素材の繊維の10〜30%を金属繊維に代替する方法が記載されている。
特開2001−252930号公報
In the same publication, as a method of imparting magnetism to the fiber-based material, a method of mixing magnetic powder such as iron powder in the binder of the fiber-based material, or a layer of magnetic powder bonded and integrated with the fiber-based material and the layer And a method of replacing 10-30% of the fibers of the fiber-based material with metal fibers.
JP 2001-252930 A

上記の磁性付与方法のうち繊維系素材のバインダーに磁性粉を混入させる方法では、磁性粉を著しく多量にバインダーに混入させると共にバインダー使用量を著しく多くしない限り、十分な磁性を付与することができないが、このようにすると、繊維系素材のしなやかさが損なわれたり、磁性粉が製品からパラパラと脱落したりするおそれがある。   Among the above-mentioned magnetism imparting methods, the method of mixing magnetic powder into the binder of the fiber-based material cannot impart sufficient magnetism unless the magnetic powder is mixed in the binder in an extremely large amount and the amount of binder used is remarkably increased. However, if it does in this way, there exists a possibility that the suppleness of a fiber type material may be impaired, or magnetic powder may fall off from a product.

磁性粉の層を繊維系素材と接着一体化させる方法でも、同様の問題がある。   There is a similar problem in the method of bonding and integrating the magnetic powder layer with the fiber material.

磁性繊維を繊維系素材の繊維の一部として用いる方法でも、繊維系素材のしなやかさが損なわれるおそれがある。また、ポリエステル繊維やアクリル繊維等の合成樹脂繊維と金属繊維とを混抄したり混編することは繊維系素材の製造コストをかなり押し上げることになる。また、比重の大きな金属繊維を10〜30%も用いると、繊維系素材の重量がかなり増加することになる。なお、金属繊維の割合を少なくしたのでは、繊維系素材に磁性を十分に付与することができず、繊維系素材を金型内面にしっかりと保持させることが難しくなる。   Even in the method of using magnetic fibers as part of the fibers of the fiber material, the flexibility of the fiber material may be impaired. In addition, blending or knitting synthetic resin fibers such as polyester fibers or acrylic fibers and metal fibers significantly increases the manufacturing cost of the fiber-based material. Moreover, when 10-30% of metal fibers having a large specific gravity are used, the weight of the fiber-based material is considerably increased. If the ratio of the metal fibers is reduced, the fiber material cannot be sufficiently magnetized, and it is difficult to hold the fiber material firmly on the inner surface of the mold.

本発明は、上記従来の問題点を解決し、繊維系素材などの副資材を容易かつ安価な手法で金型内面に保持させておくことができ、しかも繊維系素材の特性を低下させることもない発泡樹脂成形品の製造方法を提供することを目的とする。   The present invention solves the above-mentioned conventional problems, allows auxiliary materials such as fiber materials to be held on the inner surface of the mold by an easy and inexpensive method, and also reduces the properties of the fiber materials. It aims at providing the manufacturing method of a foaming resin molding which is not.

本発明(請求項1)の発泡樹脂成形品の製造方法は、金型内面に副資材を保持させ、金型内で発泡樹脂原液を発泡させることによって副資材が一体となった発泡樹脂成形品を製造する方法であって、該副資材に磁性を付与し、金型の一部に磁性体を設置し、該磁性体の磁力によって前記副資材を金型内面に保持させておくようにした発泡樹脂成形品の製造方法において、該副資材が2層以上の層を積層した積層体よりなり、該層の間のうち、該磁性体と対峙する部分にのみ磁性繊維層を介在させることにより前記副資材に磁性を付与したことを特徴とするものである。   The method for producing a foamed resin molded product of the present invention (Claim 1) is a foamed resin molded product in which the secondary material is integrated by holding the secondary material on the inner surface of the mold and foaming the foamed resin stock solution in the mold. In this method, magnetism is imparted to the secondary material, a magnetic body is installed in a part of the mold, and the secondary material is held on the inner surface of the mold by the magnetic force of the magnetic body. In the method for producing a foamed resin molded article, the auxiliary material is composed of a laminate in which two or more layers are laminated, and a magnetic fiber layer is interposed only between the layers facing the magnetic body. The auxiliary material is provided with magnetism.

請求項2の発泡樹脂成形品の製造方法は、請求項1において、前記発泡樹脂がウレタン発泡樹脂であることを特徴とするものである。   The method for producing a foamed resin molded article according to claim 2 is characterized in that, in claim 1, the foamed resin is a urethane foam resin.

請求項3の発泡樹脂成形品の製造方法は、請求項1又は2において、前記磁性繊維が磁性金属繊維であることを特徴とするものである。   According to a third aspect of the present invention, there is provided a method for producing a foamed resin molded product according to the first or second aspect, wherein the magnetic fiber is a magnetic metal fiber.

請求項4の発泡樹脂成形品の製造方法は、請求項1ないし3のいずれか1項において、前記磁性体がマグネットであることを特徴とするものである。   According to a fourth aspect of the present invention, there is provided a method for producing a foamed resin molded product according to any one of the first to third aspects, wherein the magnetic body is a magnet.

請求項5の発泡樹脂成形品の製造方法は、請求項1ないし4のいずれか1項において、前記磁性繊維層はネット状であることを特徴とするものである。   According to a fifth aspect of the present invention, there is provided a method for producing a foamed resin molded product according to any one of the first to fourth aspects, wherein the magnetic fiber layer has a net shape.

請求項6の発泡樹脂成形品の製造方法は、請求項1ないし5のいずれか1項において前記副資材が繊維系素材よりなることを特徴とするものである。   According to a sixth aspect of the present invention, there is provided a method for producing a foamed resin molded product according to any one of the first to fifth aspects, wherein the auxiliary material is made of a fiber material.

請求項7の発泡樹脂成形品の製造方法は、請求項1ないし6のいずれか1項において、積層体を構成する前記層同士が接着されていることを特徴とするものである。   The method for producing a foamed resin molded product according to claim 7 is characterized in that, in any one of claims 1 to 6, the layers constituting the laminate are bonded to each other.

本発明では、層状の副資材の層間に磁性繊維層を介在させることにより副資材に磁性を付与するようにしている。従って、例えば金型側のマグネット等の磁性体と対峙する付近にのみ磁性繊維層を配置しておくことにより、副資材全体の特性に影響を与えることなく、副資材を金型にしっかりと保持させておくのに十分な磁性を付与することができる。   In the present invention, magnetism is imparted to the secondary material by interposing a magnetic fiber layer between the layers of the layered secondary material. Therefore, for example, by arranging the magnetic fiber layer only near the magnetic material such as the magnet on the mold side, the secondary material can be held firmly in the mold without affecting the overall properties of the secondary material. Sufficient magnetism can be imparted.

また、磁性繊維層は、副資材の層間に配置されるものであるから、副資材自体は普及品を用いることができ、コストも安い。   Further, since the magnetic fiber layer is disposed between the layers of the secondary material, a popular product can be used as the secondary material itself, and the cost is low.

さらに、この磁性繊維層は、副資材の層同士の間に介在されるため、副資材の取り扱いに際して副資材から剥れたりすることがない。また、副資材を表裏反転させた場合でも、マグネット等の磁性体との距離が殆ど又は全く変化せず、副資材を金型にしっかりと磁着させることができる。   Further, since the magnetic fiber layer is interposed between the layers of the auxiliary material, the magnetic fiber layer is not peeled off from the auxiliary material when the auxiliary material is handled. Further, even when the auxiliary material is turned upside down, the distance from the magnetic material such as a magnet is hardly or not changed, and the auxiliary material can be firmly magnetically attached to the mold.

上記の副資材としては、積層が容易であるところから、繊維系素材が好適である。   As the auxiliary material, a fiber-based material is preferable because it can be easily laminated.

この繊維系素材のうち、金型側のマグネット等の磁性体に対峙する領域にのみ磁性繊維を配置することにより、繊維系素材のしなやかさを損なうことなく、また繊維系素材の重量を殆ど増加させることなく、繊維系素材を金型内面に磁力によってしっかりと保持させて成形を行うことが可能となる。   By placing the magnetic fiber only in the area facing the magnetic material such as the magnet on the mold side, the weight of the fiber material is almost increased without sacrificing the flexibility of the fiber material. Without making it possible, molding can be performed by firmly holding the fiber-based material on the inner surface of the mold by magnetic force.

なお、磁性体としてはマグネットが好適であるが、電磁石であってもよい。   In addition, although a magnet is suitable as a magnetic body, an electromagnet may be sufficient.

以下、図面を参照して本発明の実施の形態について説明する。第1図は実施の形態に係る発泡樹脂成形品の製造方法に用いられる金型を説明する断面図、第2図は第1図のマグネット付近の拡大断面図である。なお、この金型は左右対称であるので、第1図では左半分のみが図示されている。右半分は、左半分と対称に現われる。   Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a sectional view for explaining a mold used in the method for producing a foamed resin molded product according to the embodiment, and FIG. 2 is an enlarged sectional view of the vicinity of the magnet in FIG. Since this mold is symmetrical, only the left half is shown in FIG. The right half appears symmetrically with the left half.

この実施の形態に用いられる発泡成形用の金型は、自動車用シートパッドを成形するためのものであり、上型1と下型2とを備えている。この上型1と下型2はそれぞれアルミ又はアルミ合金などの非磁性金属材料よりなる。   The mold for foam molding used in this embodiment is for molding an automobile seat pad, and includes an upper mold 1 and a lower mold 2. The upper mold 1 and the lower mold 2 are each made of a nonmagnetic metal material such as aluminum or an aluminum alloy.

この上型1の内面すなわちキャビティ面には、複数個のマグネット3が設けられている。この実施の形態では、上型1の内面に凹所が設けられ、この凹所にマグネット3が嵌合されている。マグネット3はカシメ、螺じ込み、ボルト留め、接着などの固着手法によって上型1に固着されている。マグネット3の表面は、周囲の上型キャビティ面と面一状となっている。   A plurality of magnets 3 are provided on the inner surface of the upper mold 1, that is, the cavity surface. In this embodiment, a recess is provided in the inner surface of the upper mold 1, and the magnet 3 is fitted in this recess. The magnet 3 is fixed to the upper mold 1 by a fixing method such as caulking, screwing, bolting, and adhesion. The surface of the magnet 3 is flush with the surrounding upper mold cavity surface.

なお、1個のマグネット3のキャビティ面に臨む面積は1〜2000mm程度が好適である。マグネット3は、1m当り5〜50個程度配置されれば十分であるが、それよりも多少多くても、また少なくても構わない。 The area facing the cavity surface of one magnet 3 is preferably about 1 to 2000 mm 2 . It is sufficient that about 5 to 50 magnets 3 are arranged per 1 m 2 , but it may be more or less than that.

また、シート状の副資材4の端縁が対峙するキャビティ面には、マグネット3を端縁方向に所定間隔をおいて配置し、端縁がめくれないようにするのが好ましい。   Moreover, it is preferable to arrange the magnet 3 at a predetermined interval in the edge direction so that the edge does not turn over on the cavity surface where the edge of the sheet-like auxiliary material 4 faces.

副資材4は、シート状であり、この実施の形態では繊維系素材の層4a,4bを積層し、接着材で接着して一体化したものである。この副資材4の層4a,4b間のうち、マグネット3と対峙する領域には磁性繊維5が介在されている。この磁性繊維5は目開き0.1〜5mmのネット状のものが、取り扱い易く、また層4a,4b同士の接着の支障とならず好適であるが、織布又は不織布より成ってもよく、また複数本の繊維を平行に引き揃えたものであってもよい。この磁性繊維5がマグネット3に磁気的に吸着されることにより、シート状の副資材4が上型1の内面に全体として密着状に保持される。   The auxiliary material 4 is in the form of a sheet. In this embodiment, the fiber-based material layers 4a and 4b are laminated and bonded together with an adhesive material. Between the layers 4 a and 4 b of the auxiliary material 4, magnetic fibers 5 are interposed in a region facing the magnet 3. This magnetic fiber 5 having a mesh shape of 0.1 to 5 mm is easy to handle and is suitable without interfering with the adhesion between the layers 4a and 4b, but may be made of woven or non-woven fabric, A plurality of fibers may be drawn in parallel. The magnetic fiber 5 is magnetically attracted to the magnet 3 so that the sheet-like auxiliary material 4 is held in close contact with the inner surface of the upper mold 1 as a whole.

なお、この実施の形態では、副資材4の層4a,4bの厚みがほぼ等しいため、副資材4を表裏逆にした場合でも、磁性繊維5とマグネット3との距離が変らず、副資材4がマグネット3にしっかりと吸着保持される。   In this embodiment, since the thicknesses of the layers 4a and 4b of the secondary material 4 are substantially equal, even when the secondary material 4 is turned upside down, the distance between the magnetic fiber 5 and the magnet 3 does not change and the secondary material 4 does not change. Is firmly attracted and held by the magnet 3.

シートパッドの発泡成形を行うには、下型2内にウレタン原液を供給した後、上記のように副資材4が内面に磁着されている上型1を該下型2に装着して型締めを行い、ウレタンを加熱発泡させる。   In order to perform foam molding of the seat pad, after supplying the urethane stock solution into the lower mold 2, the upper mold 1 in which the auxiliary material 4 is magnetically attached to the inner surface as described above is attached to the lower mold 2. Tighten and heat foam urethane.

発泡後、型開きし、成形品を脱型する。副資材4は発泡成形品と一体となっており、上型1からスムーズに離反する。   After foaming, the mold is opened and the molded product is removed. The auxiliary material 4 is integrated with the foam molded product, and is smoothly separated from the upper mold 1.

第1図に示すキャビティセンター部6ではシートパッドのうち尻下部、腿下部などの腰掛部が成形され、キャビティサイド部7ではシートパッドのサイド部(土手部)が成形される。成形されたシートパッドの底面に副資材4が配置されることになる。   In the cavity center portion 6 shown in FIG. 1, seat portions such as the lower part of the bottom and the lower thigh of the seat pad are formed, and in the cavity side portion 7, the side portion (bank portion) of the seat pad is formed. The auxiliary material 4 is arranged on the bottom surface of the molded seat pad.

上記の磁性繊維5としては、鉄、ニッケルなどの金属糸が安価で好適であるが、強磁性金属酸化物粉末をバインダーと混練して糸状に成形した磁性糸(例えば、糸状に押し出し成形した糸や、テープ状に成形し、細く切断して糸としたものなど)であってもよい。また、強磁性金属酸化物粉体をバインダーと混練して糸に付着させた磁性糸であってもよい。さらに、合成樹脂の中空糸の孔内に強磁性体の粉体が配置された芯鞘構造の磁性糸であってもよい。   As the magnetic fiber 5, a metal thread such as iron or nickel is inexpensive and suitable, but a magnetic thread formed by kneading a ferromagnetic metal oxide powder with a binder into a thread shape (for example, a thread extruded into a thread shape) Alternatively, it may be formed into a tape shape and cut into a thin thread. Alternatively, a magnetic yarn in which a ferromagnetic metal oxide powder is kneaded with a binder and adhered to the yarn may be used. Furthermore, a magnetic yarn having a core-sheath structure in which a ferromagnetic powder is disposed in a hole of a hollow fiber of a synthetic resin may be used.

磁性繊維5の太さは、通常は100〜500μm程度が好適である。   The thickness of the magnetic fiber 5 is usually preferably about 100 to 500 μm.

副資材4が繊維系素材である場合、繊維系素材を構成する繊維としては、ポリエステル、アクリル、ポリプロピレンなどの合成樹脂繊維の織布又は不織布が例示されるが、これに限定されない。   In the case where the auxiliary material 4 is a fiber material, examples of the fiber constituting the fiber material include, but are not limited to, a woven fabric or a nonwoven fabric of synthetic resin fibers such as polyester, acrylic, and polypropylene.

上記実施の形態は本発明の一例であり、本発明は図示以外の形態をもとりうる。例えば、本発明はシートパッド以外の発泡成形品の成形にも適用できる。また、樹脂はウレタンに限定されない。副資材は繊維系素材以外のスラブウレタンフォーム等の発泡成形体などであってもよい。副資材4は3層以上から構成されてもよく、この場合、各層同士の間に磁性繊維が介在されてもよく、一部の層同士の間に磁性繊維が介在されてもよい。   The above embodiment is an example of the present invention, and the present invention may take forms other than those shown in the drawings. For example, the present invention can be applied to molding of a foam molded product other than a seat pad. The resin is not limited to urethane. The auxiliary material may be a foam molded body such as a slab urethane foam other than the fiber-based material. The auxiliary material 4 may be composed of three or more layers. In this case, magnetic fibers may be interposed between the layers, or magnetic fibers may be interposed between some layers.

実施の形態に係る成形方法を説明する断面図である。It is sectional drawing explaining the shaping | molding method which concerns on embodiment. 第1図のマグネット付近の拡大断面図である。It is an expanded sectional view of the magnet vicinity of FIG.

符号の説明Explanation of symbols

1 上型
2 下型
3 マグネット
4 副資材
5 磁性繊維
1 Upper mold 2 Lower mold 3 Magnet 4 Secondary material 5 Magnetic fiber

Claims (7)

金型内面に副資材を保持させ、金型内で発泡樹脂原液を発泡させることによって副資材が一体となった発泡樹脂成形品を製造する方法であって、
該副資材に磁性を付与し、金型の一部に磁性体を設置し、該磁性体の磁力によって前記副資材を金型内面に保持させておくようにした発泡樹脂成形品の製造方法において、
該副資材が2層以上の層を積層した積層体よりなり、該層の間のうち、該磁性体と対峙する部分にのみ磁性繊維層を介在させることにより前記副資材に磁性を付与したことを特徴とする副資材と一体の発泡樹脂成形品の製造方法。
A method for producing a foamed resin molded product in which the subsidiary material is integrated by holding the subsidiary material on the inner surface of the mold and foaming the foamed resin stock solution in the mold,
In the method for producing a foamed resin molded article, in which magnetism is imparted to the secondary material, a magnetic material is installed in a part of the mold, and the secondary material is held on the inner surface of the mold by the magnetic force of the magnetic material. ,
The secondary material is made of a laminate in which two or more layers are laminated, and magnetism is imparted to the secondary material by interposing a magnetic fiber layer only in a portion facing the magnetic material between the layers. A method for producing a foamed resin molded product integrated with a secondary material.
請求項1において、前記発泡樹脂がウレタン発泡樹脂であることを特徴とする発泡樹脂成形品の製造方法。   2. The method for producing a foamed resin molded product according to claim 1, wherein the foamed resin is a urethane foam resin. 請求項1又は2において、前記磁性繊維が磁性金属繊維であることを特徴とする発泡樹脂成形品の製造方法。   3. The method for producing a foamed resin molded product according to claim 1, wherein the magnetic fiber is a magnetic metal fiber. 請求項1ないし3のいずれか1項において、前記磁性体がマグネットであることを特徴とする発泡樹脂成形品の製造方法。   4. The method for producing a foamed resin molded product according to claim 1, wherein the magnetic body is a magnet. 請求項1ないし4のいずれか1項において、前記磁性繊維層はネット状であることを特徴とする発泡樹脂成形品の製造方法。   The method for producing a foamed resin molded product according to any one of claims 1 to 4, wherein the magnetic fiber layer has a net shape. 請求項1ないし5のいずれか1項において、前記副資材が繊維系素材よりなることを特徴とする発泡樹脂成形品の製造方法。   6. The method for producing a foamed resin molded product according to claim 1, wherein the auxiliary material is made of a fiber-based material. 請求項1ないし6のいずれか1項において、積層体を構成する前記層同士が接着されていることを特徴とする発泡樹脂成形品の製造方法。   The method for producing a foamed resin molded product according to any one of claims 1 to 6, wherein the layers constituting the laminate are bonded to each other.
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JP2011161772A (en) * 2010-02-09 2011-08-25 Bridgestone Corp Method for producing seat pad, and seat pad
JP2011161771A (en) * 2010-02-09 2011-08-25 Bridgestone Corp Method and apparatus for producing foamed molding
KR101608727B1 (en) 2014-09-29 2016-04-04 김명수 Manufacturing method of sheet foam pad integral molded felt featuring magnetism for vehicle
JP2017154278A (en) * 2016-02-29 2017-09-07 東洋紡株式会社 Nonwoven fabric for reinforcing foamed molded article
JP2021153645A (en) * 2020-03-25 2021-10-07 トヨタ紡織株式会社 Seat pad

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Cited By (8)

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JP2011161772A (en) * 2010-02-09 2011-08-25 Bridgestone Corp Method for producing seat pad, and seat pad
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JP2017154278A (en) * 2016-02-29 2017-09-07 東洋紡株式会社 Nonwoven fabric for reinforcing foamed molded article
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JP2021153645A (en) * 2020-03-25 2021-10-07 トヨタ紡織株式会社 Seat pad
JP7400581B2 (en) 2020-03-25 2023-12-19 トヨタ紡織株式会社 seat pad

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