JP2010201726A - Seat pad molding mold and method for producing seat pad using the mold - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a sheet pad molding mold which makes a film-shaped burr formed in the penetrating part of the molded sheet pad by the clearance between opposed surfaces to be removed easily and cleanly, and the residual burr, even when it is left after the removal of the film-shaped burr, hard to be seen from the entrance on the front side or the upper surface side of the sheet pad. <P>SOLUTION: A mold molds the sheet pad by a soft foamed resin. The lower mold and the upper mold or the core mold of a mold which forms the sheet pad by the lower mold and the upper mold, or the lower mold, the upper mold, and the core mold have opposed surfaces facing each other at their tips and are provided with protrusions forming a pair which form the penetrating part of the sheet pad. The clearance is opened between the opposed surfaces of the projections forming a pair. The opposed surface of the protrusion of at least one of the lower mold and the upper mold has a protrusion in the peripheral part. The protrusion of the opposed surface of the protrusion of the lower mold is positioned closely to the upper mold having the other protrusion or the core mold rather than the lower mold. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a mold for molding a sheet pad made of a soft foam resin used for a sheet of an automobile, for example, and a method for manufacturing a seat pad using the mold.

  A seat for a vehicle or the like typified by an automobile mainly includes a seat pad made of a soft foam resin at a backrest portion and a seating portion. For example, Patent Document 1 discloses a technique for improving the appearance of the skin covering by impregnating and curing a resin such as a polyurethane prepolymer at the end of the side portion of the seat pad.

  Patent Document 2 discloses that a foamable urethane material is applied to the surface of the seat pad mold of the seat pad by spraying, and then the urethane material is foam-molded integrally with the pad body. Thus, a technique for obtaining a seat pad having a high hardness in the side portion is disclosed.

  Further, in Patent Document 3, the part of the seat pad mold that forms the buckle storage part of the rear seat pad is partitioned from the other part, and the urethane material with high hardness is first added to the part that forms the buckle storage part. A technique for injecting and mitigating local hits is disclosed.

  In Patent Document 4, a protrusion is provided to face a protrusion that forms an airbag hole in the seat pad side portion of the seat pad mold, and a notch in the portion of the airbag hole in the seat pad side portion is provided. A technique for facilitating the process is disclosed.

  By the way, for example, a headrest hole through which a headrest column is passed is usually formed as a penetrating portion in the upper end portion of the seat back pad. When forming the headrest hole, usually, the seat pad mold is provided with protrusions facing each other, the headrest holes are formed from the inside and outside of the seat back pad by these protrusions, and after the seat back pad is formed, The film-like burrs formed by the gaps between the protrusions facing each other in the headrest hole are removed.

  However, it is not easy to remove the film-like burrs in the headrest hole neatly, and there is a problem that it takes time and labor, and the above Patent Documents 1 to 4 do not disclose a method for solving such a problem. .

  In addition, since the entrance radius of the headrest hole has a small rounding radius (R), there is a problem that the headrest hole entrance portion is made of a soft foam resin. Since it forms, it was not easy to prevent crushing.

Japanese Patent Laid-Open No. 02-029285 Japanese Patent Laid-Open No. 04-025415 JP 2001-169866 JP 2008-154839 A

  The present invention has been made in view of the above problems, and by improving the configuration of the molding die for forming the penetrating portion of the sheet pad made of soft foam resin, the film-like burrs in the penetrating portion can be easily and cleanly removed. An object of the present invention is to provide a seat pad mold and a method of manufacturing the seat pad using the mold, in which the entrance portion of the penetrating portion is made not to be crushed when the skin is stretched on the seat pad. .

  In order to solve the above-described problems, the present inventors diligently studied a seat pad mold that forms a through portion. As a result, if the film-like burrs formed in the gaps between the opposing surfaces of the convex portions forming a pair forming the penetrating portion become thin at the peripheral portion of the opposing surface of the projection, It was found that it can be easily removed cleanly, and even if burrs are left behind, it will not stand out if it is at the back of the penetrating part when viewed from the front side or the top side of the seat pad. It was also found that in order to make the entrance portion of the through hole difficult to be crushed, at least the entrance portion of the through hole may be formed of a material harder than the soft foam resin forming the seat pad body.

The present invention has been made on the basis of the above-described knowledge, and the gist of the present invention is as follows.
(1) In a mold for molding a seat pad with a soft foamed resin, wherein the lower pad and the upper mold or the lower pad, the upper mold and the core mold are used to mold the seat pad,
The lower mold and the upper mold or the core mold have opposing protrusions facing each other to form a penetrating portion of the seat pad, and have a pair of convex portions,
There is a gap between the opposing surfaces of the pair of convex portions,
The opposing surface of the convex part of at least one of the lower mold and the upper mold has a protruding part at a peripheral part,
The projecting portion of the opposing surface of the convex portion of the lower mold is located closer to the upper mold or the core mold having the other convex portion than the lower mold. , Seat pad mold.

(2) The seat pad is a seat back pad,
The seat pad mold according to (1) above, wherein the pair of convex portions forms a headrest hole as a penetrating portion of the seat pad.

(3) The seat pad mold according to (1) or (2), wherein the protruding portion protrudes from 1 mm to 3 mm from the facing surface.

(4) A method for producing a seat pad using the seat pad mold according to any one of (1) to (3) above,
After applying and curing an elastomer from the base to the apex of the convex part of the lower mold,
A method for producing a seat pad, wherein the elastomer is integrated with the soft foam resin by foaming and curing the raw material of the soft foam resin in the seat pad mold.

  According to the seat pad molding die of the present invention, there is a gap between the opposing surfaces of the pair of convex portions forming the seat pad penetrating portion, so the clearance between the convex portions is closed when the mold is closed. Since the opposing surface of the convex portion of at least one of the lower die and the upper die of the molding die has a protruding portion at the peripheral edge portion, a gap between the opposing surfaces is formed in the penetration portion of the molded seat pad. The thickness of the peripheral part of the film-like burr formed by this is made thinner than the center part, stress concentration is likely to occur in the peripheral part, and the film-like burr can be easily and cleanly removed. Furthermore, the protruding part of the opposing surface of the convex part of the lower mold forming the front side or the upper surface side of the seat pad is closer to the upper mold or the core type having the other convex part than the lower mold. Is left behind after removing the film-like burrs. And less visible from the inlet of the penetrating portion of the front side and the upper surface of the seat pad even, thereby improving the external appearance of the sheet.

  Further, according to the seat pad molding die of the present invention, since the pair of convex portions forms the headrest hole as the seat pad penetrating portion, it is suitable for molding the headrest hole at the upper end portion of the seat back pad of the automobile. Can be used.

  Furthermore, according to the seat pad mold of the present invention, since the protruding portion protrudes from 1 mm to 3 mm from the opposing surface, the thickness of the peripheral portion of the film-like burr is made sufficiently thinner than the central portion, The film-like burrs can be removed sufficiently easily. If the protrusion height is less than 1 mm, the difference in thickness between the central part and the peripheral part of the burr is not sufficient, and if the protrusion height exceeds 3 mm, the strength of the protrusion itself is not sufficient.

  On the other hand, according to the seat pad manufacturing method of the present invention, the elastomer is applied and cured from the base to the top of the convex portion of the lower mold of the seat pad mold, and then the soft foam resin is formed in the seat pad mold. Since the elastomer is integrated with the soft foamed resin by foaming and curing the raw material, the inner peripheral surface from the entrance to the back of the through part on the front side or upper surface side of the seat pad formed by the convex part of the lower mold Further, the film-like burrs formed in the gaps between the opposing surfaces of the convex portions forming a pair can be formed of a cured elastomer, and the film-like burrs can be more easily removed. At the same time, the entrance part of the through hole on the front side or upper surface side of the seat pad can be made harder than the soft foam resin forming the seat pad body, and it can be made difficult to be crushed when the skin is stretched on the seat pad. But It is possible to improve the appearance quality of the over door.

It is a perspective view which shows the seat back pad shape | molded with the seat pad shaping | molding die of one Embodiment of this invention. It is sectional drawing which follows the II line | wire in FIG. It is a schematic diagram which shows the longitudinal cross-section of the seat pad shaping | molding die of the said embodiment. (A)-(c) is explanatory drawing which shows the application | coating method of the elastomer to the convex part in the said seat pad shaping | molding die. It is sectional drawing which expands and shows the state in the foam molding of the soft foam resin in the said seat pad shaping | molding die. (A)-(c) is explanatory drawing which shows the removal method of the film-like burr | flash in the headrest hole of the seat back pad shape | molded with the said seat pad shaping | molding die.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view of a seat back pad molded by the seat pad mold according to one embodiment of the present invention, and FIG. 2 is a longitudinal sectional view taken along line II in FIG. In FIG. 1, reference numeral 1 denotes the seat back pad. The seat back pad 1 is used for an automobile seat. Reference numeral 2 denotes a front side of the seat back pad 1, reference numeral 3 denotes a back side of the seat back pad 1, and reference numeral 4 denotes an upper end portion of the seat back pad 1.

  As shown in FIG. 1, the seat back pad 1 has an extending portion 5 that extends from the upper end portion 4 to the back side 3 of the seat back pad 1 so that the upper portion of the seat back pad 1 has a U-shaped cross section. . Further, as shown in FIG. 2, the seat back pad 1 is formed integrally with the seat pad body 6 made of a soft foam resin on the back side 3 and the inner back surface of the extending portion 5, and the seat pad body 6 is formed. The reinforcing cloth material 7 is covered.

  The upper end 4 of the seat back pad 1 is provided with two headrest holes 8 through which the two columns of the headrest are passed as penetrating parts. The entrance of the headrest hole 8 on the front side 2 of the seat back pad 1 is provided. The inner peripheral surface of the part and the back of the hole is formed by an elastomer layer 9 integrated with the seat pad main body 6.

  As the soft foam resin that forms the seat pad body 6 of the seat back pad 1, for example, a resin such as polyurethane, polyethylene, or polystyrene can be used. As the soft foam resin that forms the seat pad body 6 of the present embodiment, A flexible polyurethane foam is used.

  The material of the reinforcing cloth material 7 is preferably a flexible material that can be three-dimensionally molded along the shape of the back surface side of the seat back pad 1 or the surface shape of the core mold 13. For example, felt, nonwoven fabric, or cloth is used. Furthermore, in order to perform thermoforming in advance so as to conform to the shape of the back surface side of the seat back pad 1 and the surface shape of the core mold 13, felt or nonwoven fabric is preferable, and felt is particularly preferable. The reinforcing cloth material 7 in the present embodiment is made of felt, and is thermoformed in advance so as to conform to the shape of the back surface side of the seat back pad 1 and the inside of the extending portion. The felt thermoforming method is not particularly limited.

  The material of the elastomer layer 9 may be, for example, an elastomer such as polyurethane, polyester, or polyamide. In consideration of adhesiveness with the seat pad body 6, an elastomer that is the same system as the seat pad body 6 is preferable. . A polyurethane elastomer is used for the elastomer layer 9 in the present embodiment.

  Next, a seat pad mold for molding the seat back pad 1 will be described. FIG. 3 is a schematic view showing a longitudinal section of the seat pad mold according to one embodiment of the present invention. In FIG. 3, the code | symbol 11 shows the said seat pad shaping | molding die. FIG. 3 also shows the reinforcing cloth material 7 disposed in the seat pad mold 11 when foaming a soft foamed resin.

  The seat pad mold 11 is a three-part mold, and has an upper mold 12, a core mold 13, and a lower mold 14. In FIG. 3, the phantom lines indicate a state where the core mold 13 is opened together with the upper mold 12. In the seat pad mold 11, the lower mold 14 forms a shape from the front side 2 to the upper end portion 4 of the seat back pad 1. The core mold 13 forms a shape on the back surface side of the seat back pad 1 and a shape on the inner side of the extending portion 5. The upper mold 12 forms the shape of the back side 3 including the shape of the outside of the extending portion 5 of the seat back pad 1.

  The symbol PL indicates a parting line between the upper mold 12 and the core mold 13. In this parting line PL, when the soft foam resin raw material liquid is injected into the seat pad mold 11 and the soft foam resin is filled in the seat pad mold 11, the gas inside the seat pad mold 11 is filled. It functions as a passage that pulls out.

  As shown in an enlarged view in FIG. 5, the lower mold 14 and the core mold 13 of the seat pad mold 11 are formed on the upper end portion 4 of the seat back pad 1. Two pairs of convex portions 15 and 16 having opposing opposing surfaces 15a and 16a at their tips are provided, and the mold is closed between the opposing surfaces 15a and 16a as shown in FIG. 4C. A predetermined gap t1 is open. The gap t1 is preferably 0.5 mm to 1.0 mm. By opening the gap t1 in this way, it is possible to secure a clearance for avoiding a collision between the convex portions 15 and 16 between the convex portions 15 and 16 when the mold is closed.

  The opposed surfaces 15a and 16a of the convex portions 15 and 16 have annular projecting portions 15b and 16b at the peripheral portions, respectively, and these projecting portions 15b and 16b are opposed to each other as shown in FIG. Projected from the surfaces 15a and 16a by heights h1 and h2, respectively. The heights h1 and h2 are preferably 1 mm to 3 mm, respectively. By providing the annular protrusions 15b and 16b in this manner, the peripheral edge of the film-like dust formed by the gap between the opposing surfaces 15a and 16a as described later in the headrest hole 8 of the molded seat back pad 1 is provided. The wall thickness can be made thinner than the central part. And the thickness of the peripheral part of the film-like garbage can be made sufficiently thinner than the center part by setting the height of the projecting parts 15b and 16b to 1.0 mm to 3.0 mm. If the heights h1 and h2 are less than 1 mm, the difference in thickness between the center part and the peripheral part of the burr 9a, which will be described later, becomes insufficient, and if the heights h1 and h2 exceed 3 mm, the strength of the protrusions 15b and 16b itself. Is not enough.

  Here, the tip of the protruding portion 15b of the facing surface 15a of the convex portion 15 of the lower mold 14 is the other convex portion than the inner surface of the lower mold 14 as shown in FIGS. 3 and 4C. 16 is located closer to the inner surface of the core die 13 having 16 and preferably protrudes from the inner surface of the lower die 14 by 10 mm or more. Accordingly, the position of the film-like dust formed by the gap between the opposing surfaces 15a and 16a is moved closer to the back surface than the top surface of the seat back pad 1 in the headrest hole 8 of the seat back pad 1, thereby 1 on the top surface of the headrest hole 8 from the entrance to the back.

  Next, a method for manufacturing the seat back pad 1 using the seat pad mold 11 will be described.

  First, as shown by phantom lines in FIG. 3, the reinforcing cloth material 7 is set on the core mold 13 in a state where the upper mold 12 and the core mold 13 are opened with respect to the lower mold 14. Next, in the mold open state, as shown in FIG. 4A, the lower mold on the surface from the base portion of the convex portion 15 of the lower mold 14 to the opposing surface 15 a and the protruding portion 15 b and around the base portion of the convex portion 15. The polyurethane prepolymer 18 is sprayed and applied onto the inner surface of the spray gun 17 with a spray gun 17, and the polyurethane prepolymer 18 is cured in about 3 to 5 seconds. As shown in FIG. An elastomer layer 9 having a thickness t2 is formed. The thickness t2 is preferably 1 to 5 mm in order to cure the polyurethane prepolymer 18 in about 3 to 5 seconds.

  Next, after injecting a predetermined amount of a foamed resin raw material liquid of flexible polyurethane foam into the lower mold 14 in the above-described mold open state, the upper mold 12 and the core mold 13 are moved with respect to the lower mold 14 as shown by a solid line in FIG. The mold is closed and a cavity C is defined inside the seat pad mold 11. At this time, as shown in FIG. 4C, the facing surface 15 a and the protruding portion 15 b of the convex portion 15 of the lower mold 14 are spaced from the facing surface 16 a and the protruding portion 16 b of the protruding portion 16 of the core mold 13. As described above, with the gap t1 of 0.5 mm to 1.0 mm being opposed to each other, the elastomer layer 9 previously formed on the opposed surface 15a of the convex portion 15 and the protruding portion 15b is formed on the opposed surface 15a. Further, it is compressed by the projecting portion 15b, the facing surface 16a and the projecting portion 16b, and a film-like disc-shaped burr 9a is formed in which the peripheral portion becomes thin with a thickness of 0.5 mm to 1.0 mm with respect to the central portion. Is done.

  Next, the flexible polyurethane foam is foam-molded by heating the cavity C of the seat pad mold 11 while maintaining the cavity C at a predetermined temperature for a predetermined time. FIG. 5 is an explanatory view showing the situation in the cavity C during foam molding. As shown in the figure, the foamed resin raw material liquid of the flexible polyurethane foam foams, and the air and the foamed gas in the cavity C are converted into the parting line PL. The seat pad main body 6 is formed by filling each part in the cavity C while venting gas. At this time, as shown in FIGS. 5 and 6A, the seat pad main body 6 and the reinforcing cloth material 7 are integrated, and the seat pad main body 6 and the elastomer layer 9 are integrated, so that the seat back pad 1 Is formed.

  After the seat back pad 1 is molded in this manner, the seat pad mold 11 is cooled, and the upper mold 12 and the core mold 13 are opened with respect to the lower mold 14 to mold the molded seat back pad 1. Die mold. At this stage, burrs 9a remain in the headrest holes 8 of the seat back pad 1 as shown in FIG. Therefore, after that, as shown in FIG. 6C, the burrs 9a in the headrest holes 8 of the seat back pad 1 are removed by pressing them with, for example, the fingertips of the fingers F, and the headrest holes 8 are penetrated. A seat back pad 1 as shown is completed. At the time of this removal, the burr 9a makes the peripheral portion thinner than the central portion by the protruding portions 15b and 16b of the convex portions 15 and 16 so that stress concentration easily occurs at the peripheral portion. It can be easily removed with just a push.

  As described above, according to the seat pad mold 11, the seat back pad 1 in which the two headrest holes 8 are provided in the upper end portion 4 can be formed, and in particular, a pair forming each headrest hole 8 is formed. Since there is a gap between the opposing surfaces 15a, 16a of the convex portions 15, 16, a clearance can be secured between the convex portions 15, 16 when the mold is closed, and the convex portion of the lower mold 14 of the molding die 11 can be secured. Since the opposing surface 15a of 15 and the opposing surface 16a of the convex part 16 of the core mold 13 have protrusions 15b and 16b at the peripheral portions, the opposing surface 15a is formed in the headrest hole 8 of the molded seat back pad 1. , 16a, the peripheral edge of the film-like burrs 9a formed by the gaps between them is made thinner than the central part, so that stress concentration easily occurs at the peripheral parts, and the film-like burrs 9a are easily cleaned. I can remove it Furthermore, the protruding portion 15b of the opposing surface 15a of the convex portion 15 of the lower mold 14 that molds the front side and the upper surface side of the seat back pad 1 is the other convex portion than the lower mold 14 Since the film-like burr 9a is left behind after the removal of the film-like burr 9a, the left-side headrest holes on the front side and the upper surface side of the seat back pad 1 are used. Thus, the appearance quality of the sheet can be improved.

  And according to the manufacturing method of the above-mentioned seat back pad 1 using the seat pad mold 11, the elastomer layer is applied and cured from the base to the apex of the convex portion 15 of the lower mold 14 of the seat pad mold 11. 9 is formed, and the elastomer layer 9 is integrated with the soft foam resin sheet pad body 6 by foaming and curing the soft foam resin material in the seat pad mold 11. In the gap between the opposed surfaces 15a and 16a of the convex portions 15 and 16 and the inner peripheral surface from the entrance to the back of the headrest hole 8 on the front side or the upper surface side of the seat back pad 1 formed by the convex portion 15. The formed film-like burr 9a can be formed of a cured elastomer, and the film-like burr 9a can be removed more easily, and the sheet bar The entrance portion of the headrest hole 8 on the front side or the upper surface side of the cup pad 1 can be made harder than the soft foam resin forming the seat pad body 6, and can be made difficult to be crushed when the skin is stretched on the seat back pad 1. In this respect as well, the appearance quality of the sheet can be improved.

  As mentioned above, although demonstrated based on embodiment of illustration, this invention is not restricted to the above-mentioned embodiment, A various change can be added within the description range of a claim. For example, in the above embodiment, the protruding portions 15b and 16b are provided on the opposing surfaces 15a and 16a of the pair of convex portions 15 and 16, respectively. However, the opposing surface 15a of the convex portion 15 of the lower mold 14 or the core mold 13 is provided. A protruding portion may be provided only on the opposing surface 16a of the convex portion 16.

  And the seat pad in the present invention may be other than the seat back pad, and the through part of the seat pad may be a part other than the headrest hole, and depending on the position of the through part in the seat pad, the pair of convex parts is the upper mold. It may be provided on the lower mold.

  According to the seat pad molding die of the present invention, there is a gap between the opposing surfaces of the pair of convex portions forming the seat pad penetrating portion, so the clearance between the convex portions is closed when the mold is closed. Since the opposing surface of the convex portion of at least one of the lower die and the upper die of the molding die has a protruding portion at the peripheral edge portion, a gap between the opposing surfaces is formed in the penetration portion of the molded seat pad. The thickness of the peripheral part of the film-like burr formed by this is made thinner than the center part, stress concentration is likely to occur in the peripheral part, and the film-like burr can be easily and cleanly removed. Furthermore, the protruding part of the opposing surface of the convex part of the lower mold forming the front side or the upper surface side of the seat pad is closer to the upper mold or the core type having the other convex part than the lower mold. Is left behind after removing the film-like burrs. And less visible from the inlet of the penetrating portion of the front side and the upper surface of the seat pad even, thereby improving the external appearance of the sheet.

  Further, according to the seat pad manufacturing method of the present invention, the elastomer is applied and cured from the base to the apex of the convex portion of the lower mold of the seat pad mold, and then the soft foam resin is formed in the seat pad mold. Since the elastomer is integrated with the soft foamed resin by foaming and curing the raw material, the inner peripheral surface from the entrance to the back of the through part on the front side or upper surface side of the seat pad formed by the convex part of the lower mold Further, the film-like burrs formed in the gaps between the opposing surfaces of the convex portions forming a pair can be formed of a cured elastomer, and the film-like burrs can be more easily removed. At the same time, the entrance part of the through hole on the front side or upper surface side of the seat pad can be made harder than the soft foam resin forming the seat pad body, and it can be made difficult to be crushed when the skin is stretched on the seat pad. But It is possible to improve the appearance quality of the over door.

DESCRIPTION OF SYMBOLS 1 Seat back pad 2 Front side 3 Back side 4 Upper end part 5 Extension part 6 Seat pad main body 7 Reinforcement cloth material 8 Headrest hole 9 Elastomer layer 9a Burr 11 Seat pad molding die 12 Upper die 13 Core die 14 Lower die 15, 16 Convex part 15a, 16a Opposing surface 15b, 16b Protrusion part 17 Spray gun 18 Polyurethane prepolymer C Cavity F Finger h1, h2 Height PL Parting line t1 Gap t2 Thickness

Claims (4)

A mold for molding a seat pad with a soft foam resin, and a molding die for molding a seat pad with a lower mold and an upper mold, or a lower mold, an upper mold and a core mold,
The lower mold and the upper mold or the core mold have opposing protrusions facing each other to form a penetrating portion of the seat pad, and have a pair of convex portions,
There is a gap between the opposing surfaces of the pair of convex portions,
The opposing surface of the convex part of at least one of the lower mold and the upper mold has a protruding part at a peripheral part,
The projecting portion of the opposing surface of the convex portion of the lower mold is located closer to the upper mold or the core mold having the other convex portion than the lower mold. , Seat pad mold. The seat pad is a seat back pad;
The seat pad forming die according to claim 1, wherein the pair of convex portions forms a headrest hole as a penetrating portion of the seat pad.   The seat pad mold according to claim 1, wherein the protruding portion protrudes 1 mm to 3 mm from the facing surface. A method for producing a seat pad using the seat pad mold according to any one of claims 1 to 3,
After applying and curing an elastomer from the base to the apex of the convex part of the lower mold,
A method for producing a seat pad, wherein the elastomer is integrated with the soft foam resin by foaming and curing the raw material of the soft foam resin in the seat pad mold.

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