JP2011213084A - Expanded molded member and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an expanded molded member which can be easily removed from a mold and also, can prevent the projecting part of a reinforcing material from becoming deformed when performing an expanded molding process of an expanded molding, and a method for manufacturing the expanded molded member.SOLUTION: This expanded molding includes a first part 3 and second parts 4 and 5 extending from the first part 3. In addition, the expanded molding is obtained by inflating an expanded synthetic resin from the first part 3 toward the second parts 4 and 5. The second part 5 is of such a shape that the part halfway through the way in the extension direction is thicker than the apex side. The reinforcing material 10 is arranged in the second part 5, and at the part halfway through the second part 5, a swelling part 13 which swells to the inner part side of the second part 5 is arranged in the reinforcing member 10. Further, on the opposite side to the second part 5 of the swelling part 13, a deformation preventive member 15 for preventing the swelling part 13 from becoming deformed during molding the expanded molding 2, is arranged.

Description

  The present invention relates to a foam-molded member comprising a foam-molded body made of a foamed synthetic resin and a planar reinforcing material disposed along at least a part of the surface of the foam-molded body. The body has a first part and a second part extending from the first part, and the foamed synthetic resin is formed by the foamed synthetic resin from the first part to the second part. The second portion has a thickness that is larger in the middle of its extending direction than the tip side, and the second portion The present invention relates to a foam-molded member in which a reinforcing material is provided, and in the middle portion of the second portion, the reinforcing material is provided with a bulging portion that bulges toward the inside of the second portion. Moreover, this invention relates to the manufacturing method of this foaming molding member.

  A seat for a vehicle or a sofa installed in a house generally has a seat pad made of a foamed synthetic resin such as a flexible polyurethane foam or a semi-rigid polyurethane foam, and a seat frame that supports the seat pad. is doing. In order to prevent the generation of noise or damage to the seat pad when the seat pad comes into contact with the seat frame, the back surface of the seat pad (the surface opposite to the seated person; the same applies hereinafter). In some cases, a reinforcing material made of a nonwoven fabric or the like may be provided. When the sheet pad with the reinforcing material is molded using a mold, the reinforcing material is previously attached to the inner surface of the mold, and the foamed synthetic resin material is foamed in the mold. Thereby, the seat pad in which the reinforcing material is integrated on the back surface is formed.

  As a seat pad, a main plate portion that comes into contact with a seated person, an extended portion that extends from the peripheral edge portion of the main plate portion to the back side of the main plate portion, and a main plate portion that extends from the distal end side in the extending direction of the extended portion. There is an overhang portion that protrudes toward the center side of the back surface, and there is an arrangement in which a seat frame is engaged with a recess surrounded by the main plate portion, the extension portion, and the overhang portion. A method for manufacturing such a seat pad is described in Japanese Patent Application Laid-Open No. 2008-183129. The seat pad manufacturing method of the same number will be described below with reference to FIG. FIG. 6 is a sectional view of a mold similar to that of FIG.

  As shown in FIG. 6, the mold 100 has an upper mold 101, a lower mold 102, and a middle mold 103 set on the upper mold 101. The front surface (seat-side surface) side of the seat pad is molded by the cavity surface of the lower mold 102, and the back surface side of the seat pad is molded by the cavity surfaces of the upper mold 101 and the middle mold 103. From the side surface of the middle mold 103, a projecting portion 104 (not mentioned in the same number) is provided so as to form the recess. That is, the main plate portion of the seat pad is formed by the cavity space 105 between the bottom surface of the cavity of the lower mold 102 and the lower surface of the middle mold 103, and the front end surface in the protruding direction of the protruding portion 104 and the cavity side surface of the lower mold 102. An extension portion of the seat pad is formed by the cavity space 106 therebetween, and an overhang portion of the seat pad is formed by the cavity space 107 between the upper surface of the protruding portion 104 and the cavity ceiling surface of the upper mold 101 (same as above). In the issue, the extension part and the overhang part are collectively referred to as the extension part.)

  When foam-molding a seat pad, a reinforcing material 110 (referred to as a sheet body in the same number) is attached to the middle mold 103, a foamed synthetic resin raw material is injected into the lower mold 102, and the upper mold 101 and the lower mold The mold 102 is clamped to foam the foamed synthetic resin material. The foamed synthetic resin raw material fills the cavity spaces 105, 106, and 107 in this order as the foaming proceeds. Thereby, the main plate part, the extension part, and the overhang part are integrally formed. In addition, the reinforcing material 110 is integrated with these back surfaces (surfaces facing the inside of the recess in the extension portion and the overhang portion). The gas in the mold 100 passes outside the mold 100 through the parting line PL between the upper mold 101 and the middle mold 103 in the projecting direction of the projecting portion (hereinafter simply referred to as the front end side). Discharged.

  As shown in FIG. 6, the cavity ceiling surface of the upper mold 101 facing the cavity space 107 is in the middle of the projecting direction of the projecting part (hereinafter simply referred to as the middle part). If it is higher than the parting line PL, gas tends to remain in the cavity space 107, and molding defects such as voids (product chips) may occur in the overhanging portion. In order to prevent this, in the same symbol, a convex portion 108 (referred to as a concave portion forming portion in the same symbol) that projects toward the cavity ceiling surface of the upper mold 101 is integrally formed on the upper surface of the protruding portion 104. Is formed. At the time of foam molding of the seat pad, the foamed synthetic resin material that has flowed into the cavity space 107 from the cavity space 106 flows over the convex portion 108 and flows to the tip side of the overhanging portion. The inside of 107 is sufficiently filled up to the cavity ceiling surface of the upper mold 101, and it is possible to prevent molding defects such as voids from occurring in the overhanging portion.

  In FIG. 3 of the same figure, instead of providing the convex portion 108 on the upper surface of the protruding portion 104, the reinforcing material 110 bulges toward the cavity ceiling surface of the upper mold 101 away from the upper surface of the protruding portion 104. It is described that a bulging portion (referred to as a convex portion in the same number) is provided. In the same reference, the bulging portion is formed by thermoforming a portion of the reinforcing member 110 that overlaps the upper surface of the protruding portion 104 into a substantially Ω-shaped cross-sectional shape. At the time of foam molding of the seat pad, since the foamed synthetic resin raw material flows to the tip side of the overhanging portion so as to get over the bulging portion in the cavity space 107, a convex portion 108 is provided on the upper surface of the protruding portion 104. Similarly to the case, the foamed synthetic resin raw material sufficiently fills the cavity space 107 to the cavity ceiling surface of the upper mold 101, thereby preventing the occurrence of molding defects such as voids in the overhanging portion.

JP 2008-183129 A

  In the aspect of FIG. 2 of the above-mentioned Japanese Patent Application Laid-Open No. 2008-183129, it is necessary to integrally form the convex portion 108 protruding toward the cavity ceiling surface of the upper die 101 on the upper surface of the protruding portion 104 of the middle die 103. The manufacturing cost of the mold may increase. Further, if the protrusion 108 protrudes from the upper surface of the protrusion 104, the protrusion 108 may be caught on the back surface of the protrusion when the seat pad is removed, and it may be difficult to remove the mold.

  In the embodiment shown in FIG. 3, instead of providing the protrusion 108 on the upper surface of the protrusion 104, the reinforcing material 110 disposed on the upper surface of the protrusion 104 is expanded toward the cavity ceiling surface of the upper mold 101. Since the protruding bulging portion is provided, it is not necessary to process the mold, and an increase in the manufacturing cost of the mold can be suppressed. Moreover, since the convex part 108 does not protrude from the protrusion part 104, it is easy to remove the seat pad. However, as described in paragraph 0021 of the same number, generally, the reinforcing material of the seat pad is made of a relatively soft material such as a non-woven fabric. The bulging portion may be deformed by pressure from the foamed synthetic resin raw material to be filled.

  The present invention eliminates the above-mentioned problems, makes it easy to remove the foam molded member from the mold, and foam molding that can prevent the bulging portion of the reinforcing material from being deformed during foam molding of the foam molded body. It aims at providing a member and its manufacturing method.

  A foam molded member of the present invention (Claim 1) is a foam comprising a foam molded body made of a foamed synthetic resin and a planar reinforcing material disposed along at least a part of the surface of the foam molded body. The foamed molded body has a first portion and a second portion extending from the first portion, and the foamed synthetic resin is made of the foamed synthetic resin. It is formed by expanding from the first part toward the second part, and the second part is thicker than the tip side in the middle part in the extending direction. The reinforcing member is disposed in the second portion, and a bulging portion bulging toward the inner side of the second portion is formed in the reinforcing member in the middle portion of the second portion. In the foamed molded member provided, the bulging part is deformed on the side opposite to the second part of the bulging part during molding of the foamed molded body. It is characterized in that the deformation preventing member for preventing is provided a.

  The foam molded member of claim 2 is the foam molded member according to claim 1, wherein the second portion has one end connected to the first portion and extending from the first portion in a direction away from the first portion. A projecting portion projecting from the other end side of the projecting portion so as to oppose the first portion in the separation direction and the crossing direction, and a surface of the projecting portion facing the first portion The reinforcing material is provided in the middle of the projecting direction of the projecting portion from the extending portion, and the bulging portion swelled to the inner side of the projecting portion is provided on the reinforcing material. The outer surface of the projecting portion opposite to the facing surface has a shape in which the middle portion in the projecting direction from the extending portion is separated from the facing surface rather than the tip side. To do.

  According to a third aspect of the present invention, in the foam molded member according to the first or second aspect, the reinforcing material is made of a nonwoven fabric.

  According to a fourth aspect of the present invention, in the foam molded member according to any one of the first to third aspects, the foam molded member is a seat pad.

  The method for producing a foam molded member according to the present invention (Claim 5) is the method for producing a foam molded member according to any one of Claims 1 to 4, wherein the reinforcing material is disposed on the inner surface of the mold. A reinforcing material disposing step, and a foam forming step of foam-molding the foamed molded body in the mold, wherein the reinforcing material is disposed on the inner surface of the mold in the reinforcing material disposing step. The bulging portion is supported on the inner surface of the mold through the deformation preventing member.

  According to a sixth aspect of the present invention, there is provided a method for producing a foam molded member according to the fifth aspect, wherein the bulging portion is a part of the reinforcing material when the reinforcing material is disposed on the inner surface of the mold in the reinforcing material disposing step. Is formed by being pushed away from the inner surface of the mold by being pushed by the deformation preventing member.

  In the present invention, a deformation preventing member for preventing deformation of the bulging portion during molding of the foam molded body is provided on the side opposite to the foam molded body of the bulging portion of the reinforcing material. In manufacturing, when the reinforcing material is disposed on the inner surface of the mold, the bulging portion is supported on the inner surface of the mold through the deformation preventing member. This prevents the bulging portion of the reinforcing material from being deformed by the pressure of the foamed synthetic resin raw material that has expanded in the mold during the molding of the foamed molded product, and more reliably molding of a void or the like in the second part. It is possible to prevent the occurrence of defects. Moreover, in this invention, since this deformation | transformation prevention member is not provided in the metal mold | die inner surface, but is provided in the foaming molding member side, the increase in the manufacturing cost of a metal mold | die can be suppressed. In addition, since the bulging portion is not caught by the mold when the foam molded member is removed, the foam molded member can be easily removed.

  In the aspect of claim 2, the second part of the foamed molded body includes an extension part extending from the first part and the extension, like the seat pad of the aforementioned Japanese Patent Application Laid-Open No. 2008-183129. A projecting portion projecting from the portion so as to face the first portion, and the outer surface of the projecting portion on the opposite side to the surface facing the first portion is an extension of the projecting portion. The middle part of the projecting direction from the part is shaped to be separated from the facing surface rather than the tip side. A reinforcing material is provided on the surface of the overhanging portion facing the first portion, and in the middle of the overhanging direction from the extending portion of the overhanging portion, the reinforcing material is provided inside the overhanging portion. A bulging portion bulging to the side is provided. According to the present invention, since the deformation preventing member prevents deformation of the bulging portion during molding of the foam molded body, it is possible to more reliably prevent the formation of voids or the like in the protruding portion. Can do.

  As described in claim 3, the present invention is suitable for a foam molded member provided with a reinforcing material made of a nonwoven fabric.

  Further, as described in claim 4, the foam molded member of the present invention is suitable for a seat pad.

  According to the sixth aspect of the present invention, when the reinforcing material is arranged on the inner surface of the mold in the reinforcing material arranging step, a part of the reinforcing material is pushed by the deformation preventing member and bulges away from the inner surface of the mold. A part is formed. With this configuration, it becomes unnecessary to form the reinforcing material into a substantially Ω-shaped cross section by thermoforming or the like as in the embodiment of FIG. 3 of the aforementioned Japanese Patent Application Laid-Open No. 2008-183129, and the manufacturing cost of the reinforcing material is reduced. In addition, the manufacturing process of the reinforcing material can be simplified.

It is explanatory drawing of the foaming molding member which concerns on embodiment. It is sectional drawing of the metal mold | die for manufacturing the foaming molding member of FIG. It is sectional drawing of the metal mold | die in the middle of manufacture of the foaming molding member of FIG. It is sectional drawing which shows the other example of a shape of a deformation | transformation prevention member. It is sectional drawing which shows the other example of a shape of a deformation | transformation prevention member. It is sectional drawing of the metal mold | die which shows the manufacturing method of the foaming molding member which concerns on a prior art example.

  Embodiments will be described below with reference to the drawings. In this embodiment, the back pad that constitutes the backrest portion of the seat pad that constitutes the vehicle seat is illustrated as the foam molded member. However, the present invention provides a seat pad other than the back pad (for example, the seat) The present invention can also be applied to a foam pad other than the seat pad, a cushion pad that constitutes a seat portion of the vehicle, a seat pad for constituting various seats other than those for vehicles, and the like.

  FIG. 1 (a) is a perspective view of a seat pad as a foam molded member according to an embodiment, and FIG. 1 (b) is a cross-sectional view taken along line BB in FIG. 1 (a). FIG. 1 (c) is an enlarged view of portion C of FIG. 1 (b). FIG. 2 (a) is a cross-sectional view of the main part of a mold for manufacturing this seat pad, and FIG. 2 (b) is a cross-sectional view taken along the line BB in FIG. 2 (a). . FIG. 2 (a) is an enlarged view of the vicinity of the cavity space for molding the upper overhanging portion of the seat pad body in the mold, and shows a cross section in the direction perpendicular to the longitudinal direction of the deformation preventing member. Yes. FIG. 3 is a cross-sectional view of the same part as FIG. 2 (a) of the mold during the manufacture of the seat pad. Hereinafter, the up-down direction, the left-right direction, and the front-rear direction are the same as the up-down direction, the left-right direction, and the front-rear direction for a seated person of a seat configured using the seat pad.

  In this embodiment, the foam molded member is a seat pad 1 constituting a vehicle seat. In particular, in this embodiment, the seat pad 1 is a back pad that constitutes a backrest portion of the seat. The seat pad 1 includes a seat pad body 2 as a foam molded body made of a foamed synthetic resin such as polyurethane foam, and a planar reinforcing material 10 disposed along the rear surface of the seat pad body 2. Yes. The reinforcing material 10 is integrated with the seat pad main body 2 by integral molding. The configuration of the mold 20 for foam-molding the seat pad body 2 and the method for manufacturing the seat pad 1 using the mold 20 will be described in detail later. The seat pad 1 has an outer surface covered with a skin material (not shown) and is attached to a back frame (not shown) of the seat.

  As shown in FIGS. 1 (a) and 1 (b), the seat pad body 2 extends rearward from the main plate portion 3 covering the front side of the back frame, and the upper side and the left and right side sides of the rear surface of the main plate portion 3, respectively. The extended portion 4 and the extended portion 5 that protrudes from the rear end of the extended portion 4 toward the center of the rear surface of the main plate portion 3. The main plate portion 3, the extension portion 4, and the overhang portion 5 are integrally formed. Moreover, the extension part 4 and the overhang | projection part 5 are continuously formed along the upper side of the rear surface of the main plate part 3, and the left and right sides. A space surrounded by the main plate portion 3, the extension portion 4, and the overhang portion 5 is a recess 6 in which the upper side and the left and right side sides of the back frame are engaged. The recess 6 is open toward the center of the rear surface of the main plate portion 3. In this embodiment, the main plate portion 3 corresponds to a first portion of claim 1 and the extension portion 4 and the overhang portion 5 correspond to a second portion. In addition, the structure of the main part of the seatpad main body 2 is not limited to this.

  In this embodiment, a protruding portion 7 that protrudes rearward is provided on the rear surface of the protruding portion 5 (hereinafter referred to as the upper protruding portion 5) along the upper side of the main plate portion 3. As shown in FIGS. 1 (b) and 1 (c), the convex portion 7 has a shape projecting most rearward in the middle portion of the upper overhanging portion 5 in the vertical direction, and the rear surface of the upper overhanging portion 5. The upper end side and the lower end side of are respectively located in front of the rearmost end portion 7p of the convex portion 7. In this embodiment, as shown in FIG. 1A, the convex portion 7 is formed continuously from the left end to the right end of the rear surface of the upper overhang portion 5. In addition, the shape and arrangement | positioning of the convex part 7 are not limited to this.

  In this embodiment, the reinforcing material 10 is made of a nonwoven fabric. In addition, the material which comprises the reinforcing material 10 is not limited to a nonwoven fabric, You may comprise by materials other than a nonwoven fabric (for example, felt, a woven fabric, a knitted fabric, etc.). In this embodiment, the reinforcing member 10 is connected to the main piece portion 11 disposed along the rear surface of the main plate portion 3, the upper side of the main piece portion 11, and the extension portion 4 on the upper side of the main plate portion 3. The upper piece portion 12 disposed along the lower surface and the front surface of the upper overhang portion 5 and the left side of the main piece portion 11 are connected to the right side surface of the left extension portion 4 and the overhang portion 5. A left side piece (not shown) arranged along the front surface and a right side of the main piece portion 11 are arranged along the left side surface of the right extension portion 4 and the front surface of the overhang portion 5. And a right side piece (not shown). The reinforcing material 10 may be one in which the main piece 11, the upper piece 12 and the left and right side pieces are continuously formed of one nonwoven fabric, and each piece is a small piece. It may be formed of a nonwoven fabric and stitched together.

  In this embodiment, as shown in FIG. 1 (c) and FIGS. 2 (a) and 2 (b), a portion along the front surface of the upper overhanging portion 5 of the upper piece 12 of the reinforcing material 10 (hereinafter referred to as the following) A bulging portion 13 that bulges rearward is provided at 12a. The bulging portion 13 is for preventing a molding defect such as a void from occurring in the upper overhanging portion 5 during foam molding of the seat pad body 2. The bulging portion 13 is formed such that the bulging portion disposing portion 12a is partially bent or curved backward, and the bulging portion 13 is a series of the bulging portion disposing portion 12a and the surrounding protruding portion disposing portion 12a. The material (nonwoven fabric) is used. The front side of the bulging portion 13 is a concave portion 14 that is recessed rearward from the front surface of the surrounding overhanging portion disposing portion 12a.

  This bulging portion 13 has a range of 50 mm upward and 50 mm downward from the rearmost end portion 7 p (FIG. 1 (c)) of the convex portion 7, particularly 20 mm upward and 20 mm downward from the most extended portion 7 p. It is preferable to form in the range. The height H (FIG. 2 (a)) from the rear surface of the overhanging portion arrangement portion 12a to the rearmost end portion of the bulging portion 13 is from the rear surface of the overhanging portion arrangement portion 12a to the rearmost end of the convex portion 7. It is preferable that it is 10 to 70%, particularly 20 to 50% of the thickness T (FIG. 2 (a)) of the upper overhanging portion 5 up to the portion 7p. In this embodiment, as shown in FIG. 2 (b), the bulging portion 13 extends in the left-right direction from the left end side to the right end side of the front surface of the upper overhang portion 5, and is a concave portion on the front surface side. 14 also has a groove shape extending in the left-right direction.

  A deformation preventing member 15 for preventing the bulging portion 13 from being deformed during foam molding of the seat pad main body 2 is provided in the recess 14. As shown in FIG. 2B, the deformation preventing member 15 extends continuously from the left end side to the right end side of the bulging portion 13. In this embodiment, the deformation preventing member 15 has a square bar-like outer shape whose cross-sectional shape in the direction perpendicular to the longitudinal direction is substantially square, and one side surface (rear surface) is the deepest portion of the recess 14. Are bonded by bonding means such as adhesion, adhesion, and sewing. In addition, the connection means to the bulging part 13 of the deformation | transformation prevention member 15 is not limited to adhesion | attachment, adhesion, and sewing. In this embodiment, as shown in FIG. 1 (c) and FIGS. 2 (a) and 2 (b), the upper surface, the lower surface, and the left and right end surfaces of the deformation preventing member 15 are not coupled to the inner surface of the recess 14. Yes. In addition, the shape of the deformation preventing member 15 and the coupling method to the inner surface of the recess 14 are not limited to this.

  The deformation preventing member 15 is made of a material having a strength that is not easily deformed by pressure from a foamed synthetic resin raw material expanded in a mold 20 to be described later when the seat pad main body 2 is foam-molded. As the material constituting the deformation preventing member 15, various materials such as foamed synthetic resin such as polyurethane foam similar to the seat pad body 2, or a fiber material such as nonwoven fabric or felt formed into a lump shape are used. Can do.

  In this embodiment, the bulging portion 13 is formed by forming the overhanging portion disposing portion 12a into a substantially Ω-shaped cross-sectional shape by thermoforming or the like as in the embodiment of FIG. 3 of the aforementioned Japanese Patent Application Laid-Open No. 2008-183129. The deformation preventing member 15 is interposed between the outer surface of the middle mold 23 and the overhanging portion 12a of the reinforcing material 10 when the reinforcing material 10 is attached to the middle mold 23 as described later. By doing so, the portion of the overhang portion 12a that overlaps the deformation prevention member 15 is separated from the outer surface of the middle mold 23 by the thickness of the deformation prevention member 15 so that the bulging portion 13 is formed. It is configured. That is, in this embodiment, the bulging portion 13 is not formed in the overhanging portion disposing portion 12a until the reinforcing member 10 is attached to the middle mold 23. With this configuration, it is not necessary to form the reinforcing member 10 into a substantially Ω-shaped cross section by thermoforming or the like as in the embodiment of FIG. 3 of Japanese Patent Laid-Open No. 2008-183129, and the manufacturing cost of the reinforcing member 10 is reduced. And the manufacturing process of the reinforcing material 10 can be simplified. In the present invention, as in the embodiment of FIG. 3 of JP-A-2008-183129, the bulging portion 13 is formed by previously forming the overhanging portion disposing portion 12a into a substantially Ω-shaped cross section by thermoforming or the like. May be.

  Edges of the reinforcing material 10 (for example, the outer peripheral edge of the reinforcing material 10 such as the lower edge of the main piece 11, the lower edge of the overhanging portion 12 a of the upper piece 12, and the side edges of the left and right side pieces In addition, a fastening means for fastening the reinforcing material 10 to the outer surface of the middle mold 23 is provided at the peripheral portion of the opening (including the cut and the like). As this fastening means, for example, the reinforcing material 10 and a magnet disposed on the outer surface of the intermediate mold 23 so as to magnetically attract the reinforcing material 10 to the outer surface of the intermediate mold 23, or the reinforcing material 10 and the intermediate mold 23 are used. Various configurations such as a clip to be connected and a double-sided tape can be used.

  Next, the metal mold | die 20 for shape | molding the seat pad main body 2 is demonstrated. As shown in FIG. 2, in this embodiment, the mold 20 has an upper mold 21, a lower mold 22, and a middle mold 23 set on the upper mold 21. Also in this embodiment, the front side of the seat pad main body 2 is formed by the cavity surface of the lower mold 22 and the cavity surfaces of the upper mold 21 and the middle mold 23 are used to form the seat pad main body 2 in the same manner as in the above-described Japanese Patent Application Laid-Open No. 2008-183129. The rear side is molded. Hereinafter, for the sake of convenience, the configuration of each part of the mold 20 will be described with the direction of each part of the mold 20 corresponding to the vertical direction, the left-right direction, and the front-rear direction of the seat pad body 2. (That is, hereinafter, the left-right direction in FIG. 2 (a) is the vertical direction, the lower part in FIG. 2 (a) is the front, the upper part in FIG. 2 (a) is the rear, and FIG. The configuration of each part of the mold 20 will be described with the direction perpendicular to the paper surface as the left and right direction.) From the upper end surface and the left and right side surfaces of the middle mold 23, projecting portions 24 for forming the recesses 6 project. . The protrusion 24 is formed continuously from the upper end surface of the middle mold 23 to the left and right side surfaces. The main plate portion 3 of the seat pad body 2 is formed by the cavity space 25 between the bottom surface of the cavity of the lower die 22 and the front surface of the middle die 23, and between the front end surface in the protruding direction of the protruding portion 24 and the cavity side surface of the lower die 22. The extended portion 4 is formed by the cavity space 26, and the protruding portion 5 is formed by the cavity space 27 between the rear surface of the protruding portion 24 and the cavity ceiling surface of the upper mold 21.

  As shown in FIG. 2A, the cavity ceiling surface of the upper mold 21 facing the cavity space 27 for forming the upper overhanging portion 5 matches the outer surface shape of the convex portion 7 on the rear surface of the upper overhanging portion 5. Thus, the middle part of the up-and-down direction of this upper side overhang | projection part 5 becomes a shape spaced apart from the rear surface of the protrusion part 24 rather than the upper end side and lower end side of this upper side overhang | projection part 5. The parting line PL between the upper mold 21 and the middle mold 23 is located on the lower end side of the upper projecting portion 5. That is, as shown in FIG. 2 (a), when the mold 20 is arranged so that the front surface of the main plate portion 3 of the seat pad main body 2 faces downward, the cavity ceiling surface of the upper mold 21 is the upper tension. In the middle of the protruding portion 5 in the vertical direction, it is higher than the parting line PL on the lower end side of the upper protruding portion 5.

  When manufacturing the seat pad 1 with the reinforcing material 10 using the mold 20, first, the upper die 21 and the lower die 22 are opened, and the reinforcing material 10 is attached to the middle die 23. At this time, as shown in FIG. 2 (a), the main piece portion 11 of the reinforcing member 10 is overlapped on the front surface of the middle mold 23, the upper piece portion 12 is covered with the upper protruding portion 24, and the overhang portion arranging portion 12a is attached to the front portion. It overlaps with the rear surface of the protrusion 24. Further, the left and right side pieces are placed on the left and right protrusions 24 (not shown). When the overhanging portion disposing portion 12a is overlapped with the rear surface of the protruding portion 24, the deformation preventing member 15 attached to the front surface of the overhanging portion disposing portion 12a protrudes as shown in FIGS. 2 (a) and 2 (b). The bulging portion 13 is formed by abutting the rear surface of the portion 24, the portion of the overhang portion disposing portion 12 a overlapping the deformation preventing member 15, and the peripheral portion thereof being separated from the rear surface of the protruding portion 24. In this embodiment, since the upper surface, the lower surface, and the left and right end surfaces of the deformation preventing member 15 are not coupled to the overhanging portion disposing portion 12a, the overhanging portion disposing portion 12a is projected by the deformation preventing member 15. When it is pushed away from the rear surface of the portion 24, the peripheral portion of the deformation preventing member 15 in the projecting portion disposing portion 12 a gently rises from the rear surface of the protruding portion 24 toward the rear end surface of the deformation preventing member 15. It becomes a slope (that is, the bulging portion 13 having a substantially trapezoidal cross-sectional shape is formed). In this embodiment, since the deformation preventing member 15 has a square bar shape with a substantially square cross section, the slope of the projecting portion disposing portion 12a and the upper surface, the lower surface, and both left and right end surfaces of the deformation preventing member 15 There is a gap between them. In order to prevent this gap from occurring, the deformation preventing member 15 may have a substantially trapezoidal cross-sectional shape in which the width in the vertical direction and the horizontal direction increases as it approaches the front surface of the overhang portion 12a. In this way, by forming the bulging portion 13 into a substantially trapezoidal cross-sectional shape that rises gently from the rear surface of the protruding portion 24, the occurrence of voids and undercuts in the vicinity of the bulging portion 13 is suppressed, and molding of the foam molded body is performed. The state can be kept good. After covering the reinforcing material 10 on the middle mold 23 in this way, the edge of the reinforcing material 10 is fastened to the outer surface of the middle mold 23 by the fastening means. Thereby, the attachment to the middle mold 23 of the reinforcing material 10 is completed.

  Next, a foamed synthetic resin raw material is injected into the lower mold 22, and the upper mold 21 and the lower mold 22 are clamped to foam the foamed synthetic resin raw material. This foamed synthetic resin raw material fills the cavity spaces 25, 26, and 27 in this order. Thereby, the main plate part 3, the extension part 4, and the overhang part 5 of the seat pad main body 2 are integrally formed. Further, the reinforcing material 10 is integrated with these back surfaces (the surfaces facing the inside of the recess 6 in the extended portion 4 and the overhang portion 5). At this time, the gas in the cavity space 27 for forming the upper overhanging portion 5 passes through the parting line PL between the upper die 21 and the middle die 23 on the lower end side of the upper overhanging portion 5 to form a mold. 20 is discharged outside.

  As described above, the cavity ceiling surface of the upper mold 21 facing the cavity space 27 is higher than the parting line PL on the lower end side of the upper overhanging portion 5 in the middle of the upper overhanging portion 5 in the vertical direction. However, the protruding portion 24a of the reinforcing member 10 disposed on the rear surface of the projecting portion 24 of the middle mold 23 facing the upper portion 21 is separated from the rear surface of the projecting portion 24. Since the bulging portion 13 bulging toward the cavity ceiling surface is formed, the foamed synthetic resin material flowing into the cavity space 27 from the cavity space 26 gets over the bulging portion 13 as shown in FIG. Thus, since the foamed synthetic resin raw material sufficiently fills the cavity space 27 to the cavity ceiling surface of the upper mold 21, the upper overhanging portion 5 and the convex portion 7 flow. Molding of voids, etc. Good is prevented from occurring.

  In the present invention, the deformation preventing member 15 is disposed between the bulging portion 13 and the rear surface of the protruding portion 24, and the bulging portion 13 is disposed on the rear surface of the protruding portion 24 via the deformation preventing member 15. Since it is supported, the bulging portion 13 is prevented from being deformed (for example, crushed) by the pressure from the foamed synthetic resin raw material filling the cavity space 27. Thereby, it is possible to prevent the occurrence of molding defects such as voids in the upper projecting portion 5 and the convex portion 7 more reliably. The bulging portion 13 is made of a material that is continuous with the surrounding bulging portion arrangement portion 12a, and the deformation preventing member 15 is covered with the material constituting the bulging portion 13. The foamed synthetic resin material does not directly contact the deformation preventing member 15. As a result, when the foamed synthetic resin raw material flows on the bulging portion 13, the foamed synthetic resin raw material is prevented from being unstable in foaming state or impregnated with the foamed synthetic resin raw material into the deformation preventing member 15. Therefore, the quality of the seat pad 1 can be improved.

  After the foamed synthetic resin filling the cavity spaces 25 to 27 is cured, the upper die 21 and the lower die 22 are opened to remove the seat pad body 2. Thereafter, a finishing operation such as deburring is performed as necessary to complete the seat pad 1.

  In the present invention, the deformation preventing member 15 is not provided so as to protrude from the upper surface of the projecting portion 24 of the middle mold 23, but is configured separately from the middle mold 23, and the swelling of the reinforcing material 10 of the seat pad 1 is expanded. Since it is attached to the front surface of the protruding portion 13, the bulging portion 13 is not caught on the rear surface of the protruding portion 24 when the seat pad main body 2 is removed, and the seat pad main body 2 can be easily removed. Can do. In addition, since the deformation preventing member 15 is configured separately from the middle mold 23 as described above, it is not necessary to process the mold 20, and an increase in mold manufacturing cost can be suppressed.

  As described above, according to the present invention, the seat pad 1 can be easily removed from the mold 20 and the bulging portion 13 of the reinforcing material 10 can be prevented from being deformed when the seat pad main body 2 is foam-molded. Therefore, the manufacturing operation of the seat pad 1 is easy, and the high-quality seat pad 1 can be manufactured with a high yield.

<Other configuration of deformation preventing member>
4 (a) to 4 (c) are cross-sectional views of the same part as FIG. 2 (a) showing another example of the shape of the deformation preventing member, and FIG. 5 (a) and FIG. 5 (b). These are sectional drawings of the same part as Drawing 2 (b) showing each other example of another shape of a deformation prevention member, respectively.

  In the above-described embodiment, the deformation preventing member 15 has a substantially square cross-sectional shape (hereinafter simply referred to as a cross-sectional shape) perpendicular to the longitudinal direction, but the shape of the deformation preventing member is not limited thereto. . For example, like the deformation preventing member 15A in FIG. 4 (a), a member having a substantially trapezoidal cross-sectional shape in which the width in the vertical direction increases as it approaches the front surface of the overhang portion 12a of the reinforcing member 10. It may have a substantially triangular cross-sectional shape with a sharp rear end as in the deformation preventing member 15B in FIG. 4 (b), and the deformation preventing member in FIG. 4 (c). As in the member 15C, the outer surface on the rear end side may have a substantially semicircular cross-sectional shape that is convexly convex toward the rear.

  In the above-described embodiment, the deformation preventing member 15 has a substantially constant thickness in the front-rear direction from the left end side to the right end side, but the thickness in the front-rear direction may be partially different. For example, the deformation preventing member 15D shown in FIG. 5 (a) is formed with a recess 16 that is recessed forward on the rear surface. In FIG. 5 (a), two recesses 16 are formed at intervals in the longitudinal direction of the deformation preventing member 15D, but the number and arrangement of the recesses 16 are not limited to this. By forming the concave portion 16 on the rear surface of the deformation preventing member 15D in this way, the height T of the bulging portion 13 is reduced in the concave portion 16, so that the foamed synthetic resin material gets over the bulging portion 13 and moves upward. It becomes easy to flow to the lower end side of the overhang part 5.

  In the above-described embodiment, the bulging portion 13 is continuous from the left end side to the right end side of the front surface of the upper overhanging portion 5. However, as shown in FIG. The portion 13 may be formed intermittently with a predetermined interval. Also when comprised in this way, it becomes easy to flow a foaming synthetic resin raw material to the lower end side of the upper side overhang | projection part 5 through between the adjacent bulging parts 13. FIG.

  In the above-described embodiment, the deformation preventing member 15 extends or is arranged in a straight line from the left end side to the right end side of the front surface of the upper overhang portion 5, but may be extended or arranged in a non-linear manner. Good.

  Each of the above embodiments is an example of the present invention, and the present invention may be configured other than illustrated.

  For example, in the above-described embodiment, the convex portion 7 is provided only on the rear surface of the upper overhang portion 5 of the seat pad main body 2, but the convex portion 7 is also provided on the rear surface of the left and right overhang portions 5 of the seat pad main body 2. May be provided. In this case, the bulging portion 13 and the deformation preventing member 15 may be provided on the left and right side pieces of the reinforcing member 10 disposed on the front surface of the left and right overhang portions 5.

  The above embodiment shows an application example of the present invention to the seat pad and the manufacturing method thereof. However, the present invention relates to the first portion other than the seat pad and the second portion connected to the first portion. A foam molded member having a foam molded body having a portion formed by expanding a foamed synthetic resin from the first portion toward the second portion. The present invention can also be applied to a certain foam molded member and a manufacturing method thereof.

1 Seat pad (foam molding member)
2 Seat pad body 3 Main plate part 4 Overhang part 5 Overhang part 6 Concave part 7 Convex part 10 Reinforcement material 11 Main piece part 12 Upper piece part 12a Overhang part arrangement part 13 Bump part 14 Concave part 15, 15A-15D Deformation Prevention member 20 Mold 21 Upper mold 22 Lower mold 23 Medium mold 24 Protrusion 25-27 Cavity space

Claims (6)

A foamed molded body made of a synthetic foam resin;
A foam-molded member provided with a planar reinforcing material disposed along at least a part of the surface of the foam-molded body,
The foamed molded article is
A first part;
A second portion extending from the first portion;
The foamed molded body is formed by the foamed synthetic resin being expanded from the first part toward the second part,
The second portion has a thickness in the middle of the extending direction that is greater than the tip side,
The reinforcing member is disposed in the second portion;
In the foamed part in which the bulging part bulged to the inner side of the second part is provided in the reinforcing material in the middle part of the second part,
A foam molded member, wherein a deformation preventing member is provided on the opposite side of the bulging portion to the second portion to prevent deformation of the bulging portion during molding of the foam molded body. The claim 2, wherein the second portion is
One end is connected to the first part, and extends from the first part in a direction away from the first part.
A projecting portion projecting in the separation direction and the crossing direction so as to face the first portion from the other end side of the extension portion;
The reinforcing material is provided on the surface of the overhanging portion facing the first portion,
In the middle of the projecting direction of the projecting part from the projecting part, the reinforcing member is provided with the bulging part that bulges to the inner side of the projecting part,
The outer surface of the projecting portion opposite to the facing surface has a shape in which a middle portion in the projecting direction from the extending portion is separated from the facing surface rather than the tip side. .   3. The foam molded member according to claim 1, wherein the reinforcing material is made of a nonwoven fabric.   4. The foam molded member according to claim 1, wherein the foam molded member is a seat pad. 5. It is a manufacturing method of the foaming molding member according to any one of claims 1 to 4,
A reinforcing material disposing step of disposing the reinforcing material on the inner surface of the mold;
A foam molding step of foam-molding the foam-molded body in the mold,
In the state in which the reinforcing material is disposed on the inner surface of the mold in the reinforcing material disposing step, the expanded portion is supported on the inner surface of the mold via the deformation preventing member. Method.   6. The bulging portion according to claim 5, wherein when the reinforcing material is arranged on the inner surface of the mold in the reinforcing material arranging step, a part of the reinforcing material is pushed by the deformation preventing member. A method for producing a foam-molded member, wherein the foam-formed member is formed by separating from the foam.

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