JP2011177958A - Method and apparatus of manufacturing foamed molding - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To surely suppress impregnation of a foaming raw material into a part corresponding to degassing holes in a reinforcing member. <P>SOLUTION: A method of manufacturing a foamed molding includes an arrangement process where the reinforcing member 3 having air permeability on a cavity face 14 with the degassing holes 12 opened is arranged in the manufacturing apparatus 10, and a molding process of molding the foamed molding by forming a foamed body 2 by foaming the foaming raw material in the cavity 11 and integrally fixing the reinforcing member 3 to the foaming body 2. In the molding process, after starting of foaming of the foaming raw material and before the foamed body 2 is formed, the communication between the inside and outside of the cavity 11 through the degassing holes 12 are blocked. A non-air permeation member 4 is attached to a part corresponding to the degassing holes 12 in the reinforcing member 3. In the molding process, when the cavity 11 is filled with the foamed foaming raw material, the degassing holes 12 is covered with the non-air permeation member 4 in a state where the reinforcing member 3 is pressed onto a cavity face 14 by the foaming raw material. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a foamed molded product in which a reinforcing member having air permeability is integrally fixed to the surface of a foamed product, and an apparatus for manufacturing the foamed molded product.

Conventionally, as a method for manufacturing a foam molded body of this type, in a foam molded body manufacturing apparatus in which a gas vent hole communicating with a cavity is formed, an arrangement step of arranging a reinforcing member on the cavity surface where the gas vent hole opens is provided. In addition, a foaming raw material is foamed in a cavity to form a foam, and a reinforcing member is integrally fixed to the foam, thereby forming a foam molded body.
In this method, during the molding process, the foamed molded body is formed while exhausting the foaming gas, air, and the like in the cavity from the vent hole through the reinforcing member having air permeability.

  However, in this method, since the inside of the cavity communicates with the outside through the gas venting hole even after the inside of the cavity is filled with the foaming raw material during the molding process, the foaming raw material is formed in the portion corresponding to the gas venting hole in the reinforcing member. Will be impregnated locally. Thereby, for example, the foaming material impregnated in the reinforcing member permeates the reinforcing member and flows into the gas vent holes, or the foaming raw material impregnates the reinforcing member so that the quality of the foamed molded product is affected. There was a risk of it.

Therefore, in order to solve such a problem, for example, it is conceivable to apply a foamed molded body manufacturing method as shown in Patent Document 1 below. In this method, first, a foaming raw material is supplied into the cavity, foamed with the gas vent hole communicated, and the expected filling time for filling the foaming raw material in the cavity is measured in advance. Thereafter, the foaming raw material is supplied into the cavity and foamed in a state where the gas vent hole is communicated, and communication between the inside of the cavity and the outside through the gas vent hole is interrupted when the scheduled filling time is reached.
According to this method, when the scheduled filling time is reached, the communication between the inside and the outside of the cavity through the gas vent hole is cut off. Impregnation of the foaming raw material can be suppressed.

JP 2003-127154 A

  However, the time required for the foaming material to be filled in the cavity is likely to vary every time the foamed molded article is manufactured, and may differ from the expected filling time. For this reason, in the conventional method for producing a foamed molded article, the communication between the inside of the cavity through the gas vent hole and the outside is not blocked even after the foaming material is actually filled in the cavity, and the gas venting of the reinforcing member is not interrupted. It was difficult to suppress the foaming raw material from being impregnated in the portion corresponding to the holes.

  The present invention has been made in view of the above-described circumstances, and an object of the present invention is to perform foam molding that can reliably suppress impregnation of the foam raw material into a portion corresponding to the gas vent hole in the reinforcing member. It is providing the manufacturing method of a body, and the manufacturing apparatus of a foaming molding.

In order to solve the above problems, the present invention proposes the following means.
The method for manufacturing a foamed molded product according to the present invention includes a foamed molded product manufacturing apparatus in which a gas vent hole communicating with a cavity is formed, and a reinforcing member having air permeability is provided on a cavity surface where the gas vent hole is opened. Foam having an arranging step of arranging and forming a foamed body by foaming a foaming raw material in the cavity and forming the foamed molded body by fixing the reinforcing member integrally to the foamed body. A method of manufacturing a molded body, wherein the molding step blocks the communication between the inside and outside of the cavity through the gas vent hole after the foaming raw material starts to foam and before the foam is formed. A non-breathable member is attached to a portion of the reinforcing member corresponding to the vent hole, and the molding step is performed when the cavity is filled with a foamed raw material filled in the cavity. The by foaming material in a state where the reinforcing member is pressed against the cavity surface, wherein said covering the gas venting holes with a non-air-permeable member from the inside of the cavity.

According to the present invention, during the molding process, after the foaming raw material starts to foam, before the foam is formed, communication between the inside and outside of the cavity through the vent hole is blocked, and when the cavity is filled Thereafter, since the communication between the inside and the outside of the cavity through the gas vent hole is blocked, it is possible to effectively suppress the impregnation of the foaming material into the portion corresponding to the gas vent hole in the reinforcing member. it can.
In addition, since the gas vent hole is covered with the non-breathable member when the cavity is filled, the portion of the reinforcing member corresponding to the gas vent hole is impregnated with the foaming raw material after the cavity is filled. It can be suppressed by the member. Therefore, even if there is a time from when the cavity is filled to when the communication between the inside and outside of the cavity through the vent hole is cut off, the impregnation of the foaming material into the reinforcing member can be suppressed during that time.
As mentioned above, it can suppress reliably that a foaming raw material impregnates the part corresponding to a gas vent hole among reinforcement members.

  In addition, as described above, since the foaming raw material can be reliably prevented from impregnating the portion corresponding to the vent hole in the reinforcing member, the foam raw material impregnates the reinforcing member and flows into the vent hole. Can be suppressed. Furthermore, it becomes possible to suppress the surface of the portion corresponding to the gas vent hole from being hardened due to the impregnation of the foam raw material, and the quality of the foam molded product. Improvements can be made.

Further, as described above, since it is possible to reliably suppress the foaming raw material from being impregnated into the portion corresponding to the gas vent hole in the reinforcing member, the foaming raw material impregnated in the reinforcing member in the conventional manufacturing method can be suppressed. , It can be used to form a foam. Therefore, it is possible to reduce the foaming raw material necessary for the production of the foamed molded product and reduce the weight of the foamed molded product.
Furthermore, since the foaming raw material required for the production of the foamed molded product can be reduced in this way, the cost of the foamed molded product can be reduced.
Furthermore, since the foamed molded body can be reduced in weight as described above, for example, when the foamed molded body is mounted on a vehicle, the fuel consumption of the vehicle can be improved, and for example, the environmental load can be reduced.

  The foam molded body manufacturing apparatus includes a magnetizing member that defines at least a part of the gas venting hole and the non-breathable member is magnetized via the reinforcing member, The step of magnetically attaching the non-breathable member to the magnetized member so that the reinforcing member is sandwiched between the non-breathable member and the magnetized member while the reinforcing member is disposed on the cavity surface. The gas vent hole may be covered from the inside of the cavity by the non-breathable member.

In this case, since the non-breathable member is magnetically attached to the magnetic adhesion member so that the reinforcing member is sandwiched between the non-breathable member and the magnetic adhesion member at the time of the arrangement step, at the time of filling the cavity in the molding step, A non-breathable member is interposed between the foaming raw material foamed in the cavity and the reinforcing member. Therefore, impregnation of the foaming raw material into the portion of the reinforcing member corresponding to the gas vent hole can be suppressed by blocking with the non-breathable member.
Also, since the gas vent hole is covered with the non-breathable member by magnetizing the non-breathable member to the magnetized member during the placement process, the non-breathable member is positioned in the gas vent hole with high accuracy in advance before the molding process. Thus, the above-described effects can be reliably achieved.

In addition, since the air-impermeable member is attached to the reinforcing member, it is possible to magnetize the air-impermeable member to the magnetized member while disposing the reinforcing member on the cavity surface during the arrangement process. Therefore, the gas vent hole can be easily covered with the non-breathable member regardless of the number of the gas vent holes provided in the foam molded body manufacturing apparatus, and the reinforcing member can be attached to the cavity surface. It becomes possible to arrange with high accuracy and ease, and the arrangement process can be easily performed.
Further, since the arrangement process can be easily performed in this manner, even when the space in the cavity is limited, the work of arranging the reinforcing member together with the non-breathable member in the cavity is complicated. Can be relaxed.

  The magnetized member may be a cylindrical magnet whose inside is the gas vent hole.

  In this case, since the magnetized member is a cylindrical magnet having a gas vent hole inside, the non-breathable member is magnetized on the magnetized member (magnet), and the gas vent hole is cavityd by the non-breathable member. By covering from the inside, not only the gas vent hole but also the opening peripheral edge of the gas vent hole can be surely covered from the inside of the cavity by the non-breathable member. Therefore, it can suppress reliably that the foaming raw material in a cavity impregnates the part which covers a gas vent hole and the part arrange | positioned at the opening peripheral part of a gas vent hole among reinforcement members.

  In addition, the magnetized member includes a degassing cylinder portion whose inside is the degassing hole, a hole defining member having a blocking wall portion that closes the degassing hole from the outside of the cavity, and an inside of the degassing hole The hole defining member may be provided with a communication path that communicates the gas vent hole with the outside of the cavity.

In this case, since the communication path is formed in the hole defining member, the flow rate of the foaming gas or air in the cavity exhausted from the gas vent hole to the outside of the cavity is set to, for example, the channel diameter or the channel length of the communication path. It can be adjusted by changing. Therefore, the flow rate of the foaming gas or air exhausted from the vent hole can be adjusted by processing the hole defining member instead of the magnet, and this adjustment can be performed relatively inexpensively.
As described above, by adjusting the flow rate of the foaming gas and air exhausted from the vent hole, it is possible to reliably suppress the foaming material in the cavity from being impregnated into the reinforcing member as the foaming gas and air are exhausted. it can.

  Further, in the arranging step, the reinforcing member is in a state where the air-impermeable member is positioned on the cavity surface side with respect to the reinforcing member and a gap is formed between the air-impermeable member and the cavity surface. Therefore, it may be arranged on the cavity surface.

  In this case, during the molding process, until the cavity is filled, the reinforcing material is pushed into the cavity surface side so that the gap between the non-breathable member and the cavity surface is narrowed by the foaming material foamed in the cavity. The foaming gas or air in the cavity is exhausted from the vent hole through the reinforcing member having air permeability and the gap. When the cavity is filled, the reinforcing member is pressed against the cavity surface by the foaming material foamed in the cavity, and the gas vent hole is covered from the inside of the cavity by the non-breathable member sandwiched between the cavity surface and the reinforcing member. Block it. As a result, even if there is a time until the communication between the inside of the cavity through the gas vent hole and the outside is cut off after the cavity is filled, the foaming gas or the like in the cavity is exhausted from the gas vent hole by the non-breathable member. It is possible to suppress the foaming raw material from being impregnated into the portion of the reinforcing member corresponding to the gas vent hole.

  The reinforcing member and the foam are integrally provided with a fixed portion that is fixed in contact with a vehicle seat frame, and the gas vent hole includes the fixed portion of the cavity surface. You may open to the formation area of the to-be-fixed part to form.

  In this case, since the gas vent hole opens in the formation region of the fixed part on the cavity surface, as described above, the portion of the reinforcing member corresponding to the gas vent hole is reliably impregnated with the foaming raw material. By being suppressed, it is possible to reliably suppress the fixed portion of the foamed molded body manufactured by this manufacturing method from becoming hard. Thereby, for example, it is possible to suppress the generation of rubbing noise between the seat frame and the fixed portion when the vehicle is traveling or seated on the seat.

  Moreover, the manufacturing apparatus of the foaming molding which concerns on this invention is a manufacturing apparatus of the foaming molding used for implementation of the manufacturing method of the said foaming molding, Comprising: While each outer peripheral part contacts, each center part mutually An upper mold and a lower mold in which the cavity is formed are provided, and a seal member for sealing between the outer peripheral parts is disposed between the outer peripheral parts of the upper mold and the lower mold. It is characterized by being.

According to this invention, since the sealing member is disposed between the outer peripheries of the upper mold and the lower mold, the foaming raw material foamed in the cavity during the molding process is the outer peripheries of the upper mold and the lower mold. Entering between them is suppressed. As a result, it is possible to suppress the formation of burrs and the like on the outer peripheral surface of the foam molded body manufactured by this foam molded body manufacturing apparatus, eliminating or reducing the deburring work after the molding process. can do.
On the other hand, since the gas vent hole is formed in the foamed molded product manufacturing apparatus, the foaming gas, air, and the like in the cavity can be reliably exhausted from the cavity through the gas vent hole.
From the above, it is possible to efficiently produce the foam molded article while reliably exhausting the foaming gas, air, and the like in the cavity.

  ADVANTAGE OF THE INVENTION According to this invention, it can suppress reliably that a foaming raw material impregnates the part corresponding to a vent hole among reinforcement members.

It is a perspective view including the partial cross section of the pad for sheets manufactured with the manufacturing method of the pad for sheets concerning a 1st embodiment of the present invention. It is the perspective view which looked at the pad for sheets shown in FIG. 1 from the back surface. It is sectional drawing which shows the metal mold | die used for the manufacturing method of the pad for sheet | seats concerning 1st Embodiment of this invention. It is AA arrow sectional drawing shown in FIG. It is one process figure of the manufacturing method of the pad for sheets concerning a 1st embodiment of the present invention. It is one process figure of the manufacturing method of the pad for sheets concerning a 1st embodiment of the present invention. It is one process figure of the manufacturing method of the pad for sheets concerning a 2nd embodiment of the present invention. It is one process figure of the manufacturing method of the pad for sheets concerning a 2nd embodiment of the present invention. It is one process figure of the manufacturing method of the pad for sheets concerning a 3rd embodiment of the present invention. It is the perspective view which looked at the pad for sheets manufactured with the manufacturing method of the pad for sheets concerning a 4th embodiment of the present invention from the back. It is one process figure of the manufacturing method of the pad for sheets concerning a 4th embodiment of the present invention. It is one process figure of the manufacturing method of the pad for sheets concerning a 4th embodiment of the present invention. It is the perspective view which looked at the pad for sheets manufactured with the modification of the manufacturing method of the pad for sheets concerning the present invention from the back. It is one process figure of the modification of the manufacturing method of the pad for sheets concerning this invention.

(First embodiment)
Hereinafter, with reference to the drawings, a sheet pad (foamed molded body) manufactured by the sheet pad manufacturing method (foamed molded body manufacturing method) according to the first embodiment of the present invention will be described.
As shown in FIG. 1, a seat pad 1 includes a reinforcing member 3 having air permeability integrally fixed to a foam 2, and the reinforcing member 3 and the foam 2 are attached to a seat frame F of a vehicle. A fixed portion 5 that is fixed in a contact state is integrally provided. The seat pad 1 shown in FIG. 1 is a so-called cushion pad that serves as a seating portion of the seat in the vehicle.

The foam 2 is formed by foaming a foaming raw material (for example, urethane raw material), and is formed of, for example, polyurethane foam. A recess 6 into which the seat frame F is fitted is formed on the back surface of the foam 2.
The reinforcing member 3 is integrally fixed to the wall surface (the surface of the foam) that defines the recess 6. The reinforcing member 3 is a film-like body having air permeability, and is formed of, for example, a cold chill, a coarse felt, or a nonwoven fabric.
The planar view shape of the seat frame F is a rectangular frame shape, and the fixed portion 5 of the seat pad 1 is provided along the outer peripheral edge portion and the side wall surface of the bottom wall surface 6 a that defines the concave portion 6. .

  As shown in FIG. 2, a portion of the fixed portion 5 corresponding to a gas vent hole 12 of a mold (foamed molded body manufacturing apparatus) 10 to be described later is not air permeable attached to the reinforcing member 3. A member 4 is provided. In the present embodiment, the non-breathable member 4 is disposed in a portion of the fixed portion 5 along the outer peripheral edge of the bottom wall surface 6a. In the illustrated example, the air-impermeable member 4 is formed in a band shape that is sandwiched between the reinforcing member 3 and the foam 2 and extends along the fixed portion 5 (the outer peripheral edge portion of the bottom wall surface 6a). For example, it is disposed over a range of 5% or more of the entire fixed portion 5.

  The non-breathable member 4 has a degree of flexibility that does not hinder the flexibility of the reinforcing member 3, such as a resin film (for example, a polyethylene film, a nylon sheet, a polyurethane, etc.), a paper tape Etc. are formed. Among these, for example, when a paper tape is employed, the non-breathable member 4 can be reliably reduced in VOC and cost.

Next, the mold 10 for manufacturing the sheet pad 1 will be described.
As shown in FIG. 3, the mold 10 is formed with a gas vent hole 12 communicating with the inside of the cavity 11 and communicating with the inside and the outside of the cavity 11, and a reinforcing member is formed on the cavity surface 14 where the gas vent hole 12 opens. In the state where 3 is disposed, the foaming raw material is foamed in the cavity 11 to form the foam 2 and the reinforcing member 3 is integrally fixed to the foam 2 to form the sheet pad 1.

In this embodiment, the mold 10 includes an upper mold 16 and a lower mold 15 in which the outer peripheral portions 15A and 16A are in contact with each other and the cavity 11 is formed between the central portions 15B and 16B. .
The central portion 15B of the lower mold 15 is recessed so as to mold the surface side of the sheet pad 1, and the central portion 16B of the upper mold 16 is provided to mold the back surface side of the sheet pad 1. ing. The upper die 16 is rotatably provided on the lower die 15 via a hinge portion, and can open and close the upper surface opening of the lower die 15. Then, the upper mold 16 closes the upper surface opening of the lower mold 15 so that the cavity surface 14 which is the surface of the central portion 16B of the upper mold 16 and the cavity surface 13 which is the surface of the central portion 15B of the lower mold 15 are interposed. A cavity 11 that is a foaming space corresponding to the shape of the sheet pad 1 is formed.

In the illustrated example, a seal member 20 that seals between the outer peripheral portions 15A and 16A is disposed between the outer peripheral portions 15A and 16A of the upper mold 16 and the lower mold 15.
The upper mold 16 and the lower mold 15 are formed of, for example, a metal material (for example, an aluminum material) having non-magnetic adhesion that is not magnetically attached to a magnet. As shown in FIG. 4, the cavity surface 14 of the upper mold 16 is provided with a fixing means 18 that fixes the reinforcing member 3 to the cavity surface 14. In the illustrated example, the fixing means 18 is formed of a magnet (for example, a permanent magnet) on which a fixed body 19 (see FIG. 5) attached to the reinforcing member 3 can be magnetically attached.

  A plurality of gas vent holes 12 are provided in the upper mold 16 and open to the cavity surface 14 of the upper mold 16. The gas vent hole 12 is open to a fixed portion forming region 17 of the cavity surface 14 that forms the fixed portion 5 of the sheet pad 1. In the illustrated example, all of the plurality of vent holes 12 are provided along the outer peripheral edge portion of the bottom wall surface 6 a in the fixed portion 5 in the fixed portion forming region 17 of the cavity surface 14. Openings are formed in the region where the part is formed with a space between each other.

  Since the foamed gas or the like in the cavity 11 is likely to remain in the fixed portion forming region 17 of the cavity surface 14, the vent hole 12 is thus opened in the fixed portion forming region 17. Thus, it is possible to effectively suppress the foaming gas or the like from remaining in the cavity 11 of the sheet pad 1.

In the present embodiment, the mold 10 further includes a gas vent pipe 21 communicating with the inside of the gas vent hole 12. In the example shown in the figure, the gas vent pipes 21 are separately provided in the plurality of gas vent holes 12, and the gas vent holes 12 communicate with the outside of the mold 10, and are detachably attached to the upper mold 16, for example. It has been. As shown in FIG. 3, the gas vent pipe 21 is provided with a valve 22 for opening and closing the gas vent pipe 21.
In this mold 10, when the valve 22 is open, the inside of the cavity 11 communicates with the outside through the gas vent hole 12 and the gas vent pipe 21. On the other hand, when the valve 22 is closed, the gas vent hole 12 is communicated. In addition, the communication between the inside of the cavity 11 and the outside through the gas vent pipe 21 is blocked.

Next, the manufacturing method of the sheet pad which forms the sheet pad 1 using this metal mold | die 10 is demonstrated.
Here, as shown in FIG. 5, the non-breathable member 4 and the fixed body 19 are respectively attached to the reinforcing member 3 in advance. The non-breathable member 4 is attached in advance to a position corresponding to the gas vent hole 12 in the reinforcing member 3. The fixed body 19 is formed of, for example, a plate-like body made of a magnetic material (iron, cobalt, nickel, etc.) or a magnet sheet with at least one surface magnetized. In the illustrated example, the fixed body 19 is attached to a surface of the reinforcing member 3 that is different from the surface to which the air-impermeable member 4 is attached, and the air-impermeable member 4 is sandwiched between the reinforcing member 3 on this surface. It is attached to avoid the part located on the opposite side. The air-impermeable member 4 and the fixed body 19 may be attached to the same surface of the reinforcing member 3.

When manufacturing the pad 1 for sheet | seats, after opening the upper mold | type 16 first, the arrangement | positioning process which arrange | positions the reinforcement member 3 in the cavity surface 14 of the upper mold | type 16 is performed. At this time, in a state where the air-impermeable member 4 is located on the opposite side of the cavity surface 14 with respect to the reinforcing member 3, the fixing member 19 is magnetically attached to the fixing means 18, whereby the reinforcing member 3 is attached to the cavity surface 14. To place.
In addition, while performing this arrangement | positioning process, a foaming raw material is thrown in in the lower mold | type 15, and the upper mold | type 16 is closed after that. In this embodiment, since the sealing member 20 is disposed between the outer peripheral portions 15A and 16A of the upper mold 16 and the lower mold 15, the outer peripheral portions 15A and 16A are in a state where the upper mold 16 is closed. The inside of the cavity 11 and the outside do not communicate with each other.

Next, a molding process for foaming the foaming raw material in the cavity 11 is performed. At this time, the foaming gas and air in the cavity 11 are exhausted from the gas vent hole 12 and the gas vent pipe 21 through the reinforcing member 3 having air permeability.
In this step, as shown in FIG. 6, when the foaming raw material continues to foam, and when the cavity is filled with the foamed foaming raw material filled in the cavity, the reinforcing member 3 is moved to the cavity surface of the upper mold 16 by the foaming raw material. 14 is pressed. Then, the gas vent hole 12 is covered from the inside of the cavity 11 by the non-breathable member 4 in a state where the reinforcing member 3 is sandwiched between the cavity surface 14 and the non-breathable member 4. Thereby, the non-breathable member 4 is interposed between the foaming raw material foamed in the cavity 11 and the reinforcing member 3, and the portion of the reinforcing member 3 corresponding to the gas vent hole 12 is impregnated with the foaming raw material. Is blocked by the non-breathable member 4.
At this time, the non-breathable member 4 is disposed along the fixed portion forming region 17. At this time, since the reinforcing member 3 is sandwiched between the cavity surface 14 and the air-impermeable member 4, the gas vent hole 12 is not completely blocked by the air-impermeable member 4.

  Then, in the molding process of the present embodiment, after the foaming raw material starts to foam, before the foam is formed, the valve 22 is closed so that the inside of the cavity 11 through the gas vent hole 12 and the gas vent pipe 21 is closed. The communication between the inside of the cavity 11 and the outside through the gas vent hole 12 and the gas vent pipe 21 is shut off after the cavity is filled. Thereby, the cavity 11 is completely sealed, and the internal pressure of the cavity 11 rises without the foaming gas or the like in the cavity 11 being exhausted from the gas vent hole 12.

  The timing for blocking communication between the inside of the cavity 11 through the gas vent hole 12 and the gas vent pipe 21 and the outside is, for example, a sensor (not shown) that detects the filling of the foaming raw material in the cavity 11 in the mold 10. And may be determined based on the detection signal of the sensor. In addition, the estimated filling time from when the foaming raw material starts to be filled in the cavity 11 until it is filled may be calculated in advance before the seat pad 1 is manufactured, and may be determined based on the estimated filling time. . In this case, for example, after a predetermined time obtained by adding a margin time to the estimated filling time has elapsed from the start of foaming of the foaming raw material in the cavity 11, the inside of the cavity 11 through the gas vent hole 12 and the gas vent pipe 21 and the outside You may block the communication with. The estimated filling time can be calculated, for example, by repeating trial evaluation of the sheet pad 1 or by simulating the foaming process of the foam material in the cavity 11.

  Then, foaming of the foaming material is stopped and resinization (resin reaction) of the foaming material proceeds, and the foam 2 is formed in the cavity 11 and the reinforcing member 3 is integrally fixed to the foam 2 to form a fixed shape. Is formed, the forming step is completed. Thereafter, the upper die 16 is opened, and the sheet pad 1 can be obtained by performing a demolding step of demolding the sheet pad 1 from the mold 10.

As described above, according to the sheet pad manufacturing method and the mold 10 according to the present embodiment, communication between the inside of the cavity 11 and the outside through the gas vent hole 12 after the cavity is filled in the molding process. Therefore, it is possible to effectively prevent the foaming raw material from being impregnated in the portion of the reinforcing member 3 corresponding to the gas vent hole 12.
Further, since the gas vent hole 12 is covered with the air-impermeable member 4 when the cavity is filled, the foaming raw material is impregnated in the portion of the reinforcing member 3 corresponding to the gas vent hole 12 after the cavity is filled. Can be suppressed by the non-breathable member 4. Therefore, even if there is a time from when the cavity is filled to when the communication between the inside of the cavity 11 through the gas vent hole 12 and the outside is cut off, the impregnation of the foaming material into the reinforcing member 3 is suppressed during that time. Can do.
As mentioned above, it can suppress reliably that a foaming raw material impregnates the part corresponding to the gas vent hole 12 among the reinforcement members 3. FIG.

Further, as described above, since the foaming raw material can be reliably prevented from impregnating the portion corresponding to the gas vent hole 12 in the reinforcing member 3, the foam raw material impregnates the reinforcing member 3 and the gas vent hole. It is possible to suppress the inflow into 12.
Further, in the present embodiment, since the gas vent hole 12 opens in the formation region 17 of the fixed portion of the cavity surface 14, as described above, to the portion corresponding to the gas vent hole 12 in the reinforcing member 3. Since the impregnation of the foaming material is surely suppressed, it is possible to reliably suppress the fixed portion 5 of the sheet pad 1 manufactured by this manufacturing method from becoming hard. As a result, for example, it is possible to suppress the generation of rubbing noise between the seat frame F and the fixed portion 5 when the vehicle is traveling or seated on the seat. The quality can be improved. In this embodiment, since the non-breathable member 4 is disposed along the fixed portion 5 in the pad 1 for the sheet, the fixed portion 5 is hardened over a wide range due to the impregnation of the foaming raw material. It becomes possible to suppress, and generation | occurrence | production of a rubbing sound can be suppressed further.

Further, as described above, since the foaming raw material can be reliably prevented from impregnating the portion corresponding to the gas vent hole 12 in the reinforcing member 3, the conventional manufacturing method impregnated the reinforcing member 3. The foaming raw material can be used for forming the foam 2. Therefore, the foaming raw material required for manufacture of the sheet pad 1 can be reduced, and the weight of the sheet pad 1 can be reduced.
Further, since the foaming raw material necessary for manufacturing the sheet pad 1 can be reduced as described above, the cost of the sheet pad 1 can be reduced.
Furthermore, since the seat pad 1 can be reduced in weight as described above, when the seat pad 1 is attached to the vehicle as in this embodiment, the fuel efficiency of the vehicle is improved, for example, the environmental load, etc. Reduction can be achieved.

In addition, since the sealing member 20 is disposed between the outer peripheral portions 15A and 16A of the upper mold 16 and the lower mold 15, the foaming raw material foamed in the cavity 11 during the molding step is the upper mold 16 and the lower mold 15. The entry between the outer peripheral portions 15A and 16A of the mold 15 is suppressed. As a result, it is possible to suppress the formation of burrs and the like on the outer peripheral surface of the sheet pad 1 manufactured with this mold 10, and eliminate or reduce the deburring work after the molding process. Can do.
On the other hand, since the gas vent hole 12 is formed in the mold 10, the foaming gas and air in the cavity 11 can be reliably exhausted from the cavity 11 through the gas vent hole 12.
As described above, the sheet pad 1 can be efficiently manufactured while the foaming gas, air, and the like in the cavity 11 are reliably exhausted.

  In the present embodiment, the fixing means 18 is formed of a magnet that can be magnetically attached to the fixed body 19 attached to the reinforcing member 3. Instead, for example, the fixing member 18 penetrates the reinforcing member 3. By doing so, you may form in the pin shape fixed. In this case, the fixed body 19 may be omitted.

(Second Embodiment)
Next, the metal mold | die 30 used with the manufacturing method of the pad for sheets of 2nd Embodiment which concerns on this invention is demonstrated with reference to FIG.
In the second embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, description thereof is omitted, and only different points will be described. Further, in the drawings shown below, the illustration of the gas vent pipe 21 is omitted for easy viewing.
As shown in FIG. 7, the mold 30 includes a magnetized member 31 that defines the gas vent hole 12. The upper mold 16 of the mold 30 is formed with a plurality of through holes 32 that open to the cavity surface 14, and the magnetized members 31 are individually mounted in the through holes 32.

  A non-breathable member 34 attached to the reinforcing member 3 is magnetically attached to the magnetized member 31 via the reinforcing member 3. In this embodiment, the magnetized member 31 is a cylindrical magnet 33 whose inside is a gas vent hole 12. The magnet 33 is formed of a permanent magnet and is fitted into the through hole 32, and the end surface inside the cavity 11 of the magnet 33 is smoothly connected to the cavity surface 14 of the upper mold 16 and is flush with the surface. Further, the air-impermeable member 34 has a plate shape, and is formed of, for example, a plate-like body made of a magnetic material (iron, cobalt, nickel, etc.), a magnet sheet with at least one surface magnetized, or the like.

  Next, a method for manufacturing a sheet pad for forming the sheet pad 1 using the mold 30 will be described. Here, a non-breathable member 34 is attached to the reinforcing member 3 at a position corresponding to the gas vent hole 12 in advance.

  First, as shown in FIG. 7, the arrangement step is performed. At this time, in the present embodiment, the reinforcing member 3 is placed on the cavity surface 14 of the upper die 16 and the reinforcing member 3 is not sandwiched between the non-breathable member 34 and the magnetized member 31 (magnet 33). The breathable member 34 is magnetically attached to the magnetic attachment member 31. As a result, the gas vent hole 12 is covered from the inside of the cavity 11 by the non-breathable member 34. In the illustrated example, the opening peripheral edge portion 12 a of the gas vent hole 12 in the cavity surface 14 is also covered from the inside of the cavity 11 by the non-breathable member 34.

  Thereafter, as shown in FIG. 8, the forming step is performed. Here, in the present embodiment, the non-breathable member 34 is magnetically attached to the magnetic member 31 so that the reinforcing member 3 is sandwiched between the non-breathable member 34 and the magnetic member 31. When the cavity is filled, the air-impermeable member 34 is interposed between the foaming raw material foamed in the cavity 11 and the reinforcing member 3. Therefore, impregnation of the foaming raw material into the portion of the reinforcing member 3 corresponding to the gas vent hole 12 can be suppressed by blocking with the non-breathable member 34.

  As described above, according to the sheet pad manufacturing method of the present embodiment, the non-breathable member 34 magnetically attaches the non-breathable member 34 to the magnetized member 31 during the placement step, thereby causing the gas-permeable holes to be vented. 12 is covered, it is possible to position the non-breathable member 34 in the gas vent hole 12 in advance with high accuracy before the molding step, and the above-described effects can be achieved more reliably.

Further, since the magnetized member 31 is a cylindrical magnet 33 with the inside being the gas vent hole 12, the non-breathable member 34 is magnetized on the magnetized member 31 (magnet 33), and the non-breathable member 34. By covering the gas vent hole 12 from the inside of the cavity 11, not only the gas vent hole 12 but also the opening peripheral portion 12 a of the gas vent hole 12 can be reliably covered from the inside of the cavity 11 by the non-breathable member 34. become. Therefore, it is possible to reliably suppress the portion of the reinforcing member 3 that covers the gas vent hole 12 and the portion disposed at the opening peripheral edge portion 12a of the gas vent hole 12 from being impregnated with the foaming material in the cavity 11. .
In addition, as described above, the portion of the reinforcing member 3 that covers the gas vent hole 12 and the portion disposed at the opening peripheral edge portion 12a of the gas vent hole 12 are reliably suppressed from being impregnated with the foaming raw material in the cavity 11. Therefore, it is possible to reliably suppress the foaming raw material from flowing into the gas vent hole 12.

Further, since the air-impermeable member 34 is attached to the reinforcing member 3, the air-impermeable member 34 is magnetically attached to the magnetized member 31 while the reinforcing member 3 is disposed on the cavity surface 14 during the arrangement process. It becomes possible. Therefore, the gas vent holes 12 can be easily covered with the non-breathable member 34 regardless of the number of the gas vent holes 12 provided in the mold 10, and the reinforcing member 3 is attached to the cavity surface 14. On the other hand, it becomes possible to arrange with high precision and easily, and the arrangement process can be easily performed.
Further, since the arrangement process can be easily performed as described above, the reinforcing member 3 is positioned in the cavity 11 together with the air-impermeable member 34 even when the space in the cavity 11 is restricted. The complexity of the work to be performed can be reduced.

  The magnetized member 31 only needs to define at least a part of the vent hole 12. For example, the magnetized member is a magnet attached to the inner peripheral surface of the through hole 32, and the inner periphery of the through hole 32. The gas vent hole 12 may be defined together with a portion of the surface where the magnetized member is not attached.

(Third embodiment)
Next, the metal mold | die used with the manufacturing method of the pad for sheets of 3rd Embodiment concerning this invention is demonstrated with reference to FIG.
Note that in the third embodiment, the same components as those in the second embodiment are denoted by the same reference numerals, description thereof is omitted, and only different points will be described.
As shown in FIG. 9, the magnetized member 41 of the mold 40 includes a degassing cylinder portion 42 whose inside is a degassing hole 12, and a blocking wall portion that closes the degassing hole 12 from the outside of the cavity 11. A hole defining body 44 having 43 and a magnet 46 fixed in the gas vent hole 12 are provided.

  In the illustrated example, the degassing cylinder portion 42 is fitted into the through hole 32, and the end surface inside the cavity 11 of the degassing cylinder portion 42 is smoothly connected to the cavity surface 14 of the upper mold 16 and is flush with the surface. It has become. Further, the closing wall portion 43 closes the opening end portion outside the cavity 11 of the degassing cylinder portion 42, and the hole defining member 44 has a top-like cylindrical shape that opens inside the cavity 11 as a whole. .

  The magnet 46 is formed in a rod shape extending along the axial direction in the gas vent hole 12, is fixed to the closing wall portion 43 of the hole defining member 44, and extends from the center of the closing wall portion 43 to the cavity 11. It extends towards the inside. The end surface inside the cavity 11 of the magnet 46 is flush with the cavity surface 14 of the upper mold 16. The non-breathable member 34 is magnetically attached to the magnet 46 via the reinforcing member 3.

The hole defining body 44 is formed with a communication passage 45 that allows the gas vent hole 12 to communicate with the outside of the cavity 11. In the example shown in the drawing, a plurality of communication passages 45 are formed at intervals in the circumferential direction in a portion of the gas vent cylinder portion 42 located outside the cavity 11.
In the mold 40, foaming gas, air, and the like in the cavity 11 are exhausted through the gas vent hole 12 and the communication path 45.

As described above, according to the sheet pad manufacturing method according to the present embodiment, since the communication passage 45 is formed in the hole defining member 44, the air is exhausted from the gas vent hole 12 to the outside of the cavity 11. The flow rates of the foaming gas and air in the cavity 11 can be adjusted by changing the flow path diameter and flow path length of the communication path 45, for example. Therefore, the flow rate of the foaming gas or air exhausted from the gas vent hole 12 can be adjusted by processing the hole defining body 44 instead of the magnet 46, and this adjustment can be performed relatively inexpensively. .
If the flow rate of the foaming gas or air in the cavity 11 exhausted from the gas vent hole 12 is adjusted in this way, the foaming material in the cavity 11 is impregnated into the reinforcing member 3 as the foaming gas or air is exhausted. Can be suppressed.

(Fourth embodiment)
Next, a sheet pad 50 manufactured by the sheet pad manufacturing method according to the fourth embodiment of the present invention will be described with reference to FIG.
In the fourth embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, description thereof is omitted, and only different points will be described.
As shown in FIG. 10, in this sheet pad 50, the non-breathable member 4 is disposed and exposed on the surface of the fixed portion 5.

Next, a sheet pad manufacturing method for manufacturing the sheet pad 50 using the mold 10 will be described.
Here, as shown in FIG. 11, the non-breathable member 4 and the fixed body 19 are attached to the reinforcing member 3 in advance on the same surface of the reinforcing member 3. The fixed body 19 may be attached to a different surface from the non-breathable member 4.

  First, the arrangement step is performed. At this time, in the present embodiment, the reinforcing member 3 is configured such that the air-impermeable member 4 is positioned on the cavity surface 14 side with respect to the reinforcing member 3 and a gap 51 is formed between the air-impermeable member 4 and the cavity surface 14. In this state, it is arranged on the cavity surface 14. As described above, since the reinforcing member 3 is disposed with the gap 51 between the non-breathable member 4 and the cavity surface 14, the foaming gas and air in the cavity 11 are permeable to the reinforcing member 3. The gas is exhausted from the vent hole 12 through the gap 51.

Next, the molding step is performed. In this step, the reinforcing member 3 is pushed toward the cavity surface 14 so that the gap 51 between the air-impermeable member 4 and the cavity surface 14 is narrowed by the foaming raw material foamed in the cavity 11 until the cavity is filled. The foaming gas and air in the cavity 11 are exhausted from the vent hole 12 through the reinforcing member 3 and the gap 51. Then, as shown in FIG. 12, when the cavity is filled, the reinforcing member 3 is pressed against the cavity surface 14 by the foaming material foamed in the cavity 11 and sandwiched between the cavity surface 14 and the reinforcing member 3. The gas vent hole 12 is covered and closed from the inside of the cavity 11 by the member 4. Thereby, it is possible to suppress the foaming gas or the like in the cavity 11 from being exhausted from the gas vent hole 12.
In this way, since the air-impermeable member 4 is sandwiched between the cavity surface 14 and the reinforcing member 3 during the molding step, the surface of the portion corresponding to the gas vent hole 12 in the fixed portion 5. The non-breathable member 4 that is difficult to be impregnated with the foaming raw material is disposed.

  As described above, according to the sheet pad manufacturing method of the present embodiment, it is assumed that there is a time until the communication between the cavity 11 through the gas vent hole 12 and the outside is cut off after the cavity is filled. However, the non-breathable member 4 can suppress the foaming gas or the like in the cavity 11 from being exhausted from the vent hole 12, and the reinforcing member 3 is foamed at a portion corresponding to the vent hole 12. Impregnation of the raw material can be suppressed.

The technical scope of the present invention is not limited to the above embodiment, and various modifications can be made without departing from the spirit of the present invention.
For example, in each of the embodiments described above, the mold 10 includes the upper mold 16 and the lower mold 15, but may be configured to include a core mold disposed in the cavity 11 in addition to these. .
In each of the above embodiments, the seal member 20 is disposed between the outer peripheral portions 15A and 16A of the upper mold 16 and the lower mold 15. However, the seal member 20 may not be provided.

Moreover, in each said embodiment, although the air-impermeable members 4 and 34 shall be strip | belt shape extended along the said to-be-fixed part 5 of the pad 1 for sheets, it is not restricted to this. For example, a plurality of non-breathable members 61 may be disposed along the fixed portion 5 at intervals from each other, like a sheet pad 60 shown in FIG.
As shown in FIG. 14, for example, the sheet pad 60 includes a reinforcing member in which a plurality of non-breathable members 61 are respectively attached in advance to positions corresponding to the plurality of gas vent holes 12 before the arrangement step. 3 can be used.
However, the non-breathable member preferably extends along the fixed portion 5 of the seat pad 1 from the viewpoint of impregnation of the foaming material and generation of rubbing noise.
Furthermore, in each said embodiment, although the air-impermeable member 4,34,61 shall be arrange | positioned along the said to-be-fixed part 5 of the pad 1,50,60 for sheets, It does not have to be along.

Moreover, in each said embodiment, although the metal mold | dies 10, 30, and 40 shall have been formed with two or more degassing holes 12, one may be sufficient.
Further, in each of the above embodiments, the plurality of gas vent holes 12 are opened at intervals from each other along the formation region 17 of the fixed portion of the cavity surface 14. However, the present invention is not limited to this. Absent. For example, one gas vent hole 12 may be opened in the shape of a long hole extending along the formation region 17 of the fixed portion.

  Further, in each of the above embodiments, the gas vent hole 12 is opened in the fixed portion forming region 17 of the cavity surface 14, but may not be opened in the fixed portion forming region 17. good. Even in this case, it becomes possible to suppress that the surface of the portion corresponding to the gas vent hole 12 of the sheet pad manufactured by this manufacturing method becomes hard due to the impregnation of the foaming raw material, The quality of the seat pad can be improved.

In each of the above embodiments, the planar view shape of the seat frame F is a rectangular frame shape, but is not limited thereto.
Furthermore, in each said embodiment, although the recessed part 6 shall be formed in the foam 2, the recessed part 6 does not need to be.

Further, in each of the embodiments, the fixed portion 5 is provided along the outer peripheral edge portion and the side wall surface of the bottom wall surface 6a that defines the concave portion 6, but is not limited thereto. is not. For example, the fixed portion 5 may be provided integrally with the foam 2 and the reinforcing member 3 in which the recess 6 is not formed.
Furthermore, in each said embodiment, although the said to-be-fixed part 5 shall be integrally provided in the reinforcement member 3 and the foam 2, the said to-be-fixed part 5 does not need to be.

  In each of the above embodiments, so-called cushion pads are employed as the seat pads 1, 50, 60. However, the present invention is not limited to this, and for example, a so-called back pad that serves as a seat back portion in the vehicle. May be.

  In addition, it is possible to appropriately replace the constituent elements in the embodiment with known constituent elements without departing from the spirit of the present invention, and the above-described modified examples may be appropriately combined.

Next, the verification test about the effect demonstrated above was implemented.
In this verification test, a total of five sheet pad manufacturing methods of Examples 1 and 2 and Comparative Examples 1 to 3 were performed.
Here, in Examples 1 and 2 and Comparative Examples 1 to 3, the mold shown in the first embodiment was used, and when the foaming raw material started to foam, the foamed raw material was used after 45 seconds. Conditions such as raw material and mold temperature were fixed so that the cavity was filled. In addition, the filling of the foaming raw material in the cavity was detected by a pressure-sensitive sensor provided at the corner (end) of the cavity.

  In Examples 1 and 2, a sheet pad was manufactured by the method for manufacturing a sheet pad shown in the first embodiment. In Example 1, the timing for blocking the communication between the inside and outside of the cavity through the vent hole during the molding process is the time when the cavity is filled 45 seconds after the foaming raw material starts to foam, and Example 2 Then, the timing was set to 55 seconds after the foaming raw material started to foam (that is, 10 seconds after the cavity was filled).

  Moreover, in Comparative Examples 1-3, the pad for sheets was manufactured with the manufacturing method of the pad for sheets using the reinforcement member to which the non-breathable member is not attached. In Comparative Example 1, the timing for blocking the communication between the inside and outside of the cavity through the vent hole during the molding process is the time when the cavity is filled 45 seconds after the foaming raw material starts to foam, and Comparative Example 2 Then, the timing is set to 55 seconds after the foaming raw material starts to foam, and in Comparative Example 3, communication between the inside of the cavity through the gas vent hole and the outside was not blocked.

And all of Example 1, 2 and Comparative Examples 1-3 obtained the pad for sheet | seats by performing a demolding process after progress for 5 minutes, after the foaming raw material began to foam. Thereafter, the portion corresponding to the gas vent hole in the fixed portion of the sheet pad was touched with a finger to determine the degree of impregnation of the foaming material into the reinforcing member.
The results are shown in Table 1.

  As shown in Table 1, while Examples 1 and 2 and Comparative Example 1 are all impregnated and the hardening of the reinforcing member is suppressed, Comparative Examples 2 and 3 are excessively impregnated and the reinforcing member becomes hard. It was confirmed that From these, in the present invention, even if there is a variation of about 10 seconds from the time when the cavity is filled to the time when communication between the inside and outside of the cavity through the vent hole is interrupted, impregnation of the foaming raw material into the reinforcing member It was confirmed that it can be suppressed.

1, 50, 60 Pad for sheet (foam molding)
2 Foam 3 Reinforcing member 4, 34, 61 Non-breathable member 5 Fixed portion F Seat frame 10, 30, 40 Mold (Foamed molded body manufacturing apparatus)
11 Cavity 12 Gas vent hole 14 Cavity surface 15 Lower mold 16 Upper mold 15A, 16A Outer peripheral part 15B, 16B Central part 17 Fixed part forming area 20 Seal member 31, 41 Magnetic adhesion member 33, 46 Magnet 42 Gas vent cylinder part 43 Blocking wall 44 Hole defining member 45 Communication path 51 Crevice

Claims (7)

In the foamed molded article manufacturing apparatus in which a vent hole communicating with the inside of the cavity is formed, an arrangement step of disposing a reinforcing member having air permeability on the cavity surface where the vent hole is opened;
Forming a foam by foaming a foaming raw material in the cavity and forming the foam molded body by integrally fixing the reinforcing member to the foam. There,
In the molding step, after the foaming raw material starts to foam and before the foam is formed, the communication between the inside and the outside of the cavity through the gas vent hole is interrupted,
A non-breathable member is attached to a portion corresponding to the gas vent hole in the reinforcing member,
In the molding step, the gas vent hole is formed by the non-breathable member while the reinforcing member is pressed against the cavity surface with the foamed raw material when the inside of the cavity is filled with the foamed foamed raw material. A method for producing a foamed molded article, wherein the foamed article is covered from the inside of a cavity. It is a manufacturing method of the foaming fabrication object according to claim 1,
The foamed molded body manufacturing apparatus includes a magnetic adhesion member that defines at least a part of the gas vent hole and that the air-impermeable member is magnetically bonded via the reinforcing member.
In the arranging step, the non-breathable member is placed on the magnetic adhesion member so that the reinforcement member is sandwiched between the non-breathable member and the magnetic adhesion member while the reinforcement member is disposed on the cavity surface. A method for producing a foamed molded article comprising magnetizing and covering the gas vent hole from the inside of the cavity with the non-breathable member. It is a manufacturing method of the foaming molding according to claim 2,
The method for producing a foamed molded article, wherein the magnetized member is a cylindrical magnet having an inside formed as the vent hole. It is a manufacturing method of the foaming molding according to claim 2,
The magnetized member is fixed in the gas vent hole, and a hole defining member having a gas vent cylinder portion whose inside is the gas vent hole, and a blocking wall portion that closes the gas vent hole from the outside of the cavity. And a magnet to be
A method for producing a foamed molded article, wherein the hole defining body is formed with a communication path that communicates the gas vent hole and the outside of the cavity. It is a manufacturing method of the foaming fabrication object according to claim 1,
In the arranging step, the reinforcing member is in a state where the air-impermeable member is positioned on the cavity surface side with respect to the reinforcing member and a gap is formed between the air-impermeable member and the cavity surface. A method for producing a foam-molded article, wherein the foam-molded article is disposed on the cavity surface. It is a manufacturing method of the foaming fabrication object according to any one of claims 1 to 5,
The reinforcing member and the foam are integrally provided with a fixed portion that is fixed in contact with a vehicle seat frame,
The method for producing a foamed molded product, wherein the gas vent hole is opened in a formation region of a fixed portion that forms the fixed portion in the cavity surface. It is a manufacturing apparatus of a foaming molding used for implementation of a manufacturing method of a foaming molding of a statement in any 1 paragraph of Claims 1-6,
Comprising an upper mold and a lower mold in which the outer peripheral portions are in contact with each other and the cavity is formed between the central portions of each other;
A sealing member for sealing between the outer peripheral portions is disposed between the outer peripheral portions of the upper mold and the lower mold.

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