JP2013111771A - Molding apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To decrease the number of components of a molding apparatus and furthermore to excellently mold a foam molded product.SOLUTION: A molding apparatus 10 includes a first mold 11, a second mold 12 which can be closed to the first mold 11, and a cavity 14 formed between the first mold 11 and second mold 12, and molds a cushion material for a vehicle sheet by foaming a molding material in the cavity 14. The molding apparatus 10 is constituted in such a manner that: at least one of the first mold 11 and second mold 12 is provided with a plurality of recessed parts 30 which do not communicate with outside of the molding apparatus 10; and a gas staying in the cavity 14 is allowed to flow in the plurality of recessed parts 30 during foaming of the molding material.

Description

  The present invention relates to a molding apparatus capable of molding a foam molded product (such as a cushion material for a vehicle seat).

As this type of molding apparatus, a molding apparatus including a first mold, a second mold, a cavity, and a gas (air or foamed gas) discharge means is known (see Patent Document 1).
In this molding apparatus, for example, a cushion material for a vehicle seat (an example of a foam molded product) can be molded. This type of cushioning material is a member that elastically supports an occupant with a seat outer shape, and is formed of a foamed resin such as polyurethane foam.
The first mold and the second mold are mold members that can be closed to each other, and a cavity (a space portion that follows the outer shape of the cushion material) can be formed between the two molds. The discharge means is a pipe portion that penetrates the second mold in the thickness direction, and communicates the cavity and the outside of the apparatus.

Then, when molding the cushion material, the discharge port of the discharge means (the pipe portion protruding to the cavity side) is covered with a breathable material. The breathable material is attached to the discharge port in a pierced state with, for example, a dedicated holder. Here, the breathable material is a member made of, for example, a slab chip, and impregnation of the molding material is suppressed as much as possible by waterproofing treatment.
Next, after closing the first mold and the second mold, the cushioning material is molded by foaming the molding material in the cavity. At this time, the gas in the cavity is discharged from the discharge port to the outside of the apparatus while preventing the molding material from flowing out from the discharge means by the breathable material. By discharging the stagnant gas from the cavity in this way, it is possible to prevent the occurrence of a chipped portion of the cushion material (a dent portion that is generated when the stagnant gas in the cavity is collected in one place) as much as possible.

JP 2003-205187 A

By the way, in a well-known technique, the outflow of the molding material is prevented by covering the discharge port with a breathable material.
However, the configuration of the known technology (configuration in which a breathable material is essential) has not been a configuration that can be easily adopted from the viewpoint of reducing the number of parts of the molding apparatus. In addition, the work of placing a breathable material at the time of molding the cushion material (the work of piercing the breathable material into the tube portion) was somewhat troublesome.
The present invention has been devised in view of the above points, and the problem to be solved by the present invention is to satisfactorily mold a foam-molded product while reducing the number of parts of the molding apparatus.

As means for solving the above-mentioned problems, a molding apparatus according to a first invention includes a first mold, a second mold that can be closed to the first mold, and a cavity formed between the first mold and the second mold. And have.
Then, the molding material in the cavity is foamed to form a foam molded product such as a cushion material for a vehicle seat. In this type of apparatus configuration, it is desirable that the foamed molded article can be molded well while reducing the number of parts of the molding apparatus.

Therefore, in the present invention, at least one of the first mold and the second mold is provided with a plurality of recesses that are not in communication with the outside of the molding apparatus. And it was set as the structure which can flow in the gas which stays in a cavity at the time of foaming of a molding material into a some recessed part.
In the present invention, the cushioning material can be satisfactorily formed (without using a gas-permeable material or a discharging means) by flowing the staying gas in the cavity into the plurality of recesses.

The molding apparatus of the second invention is the molding apparatus of the first invention, wherein the plurality of recesses described above are provided on the downstream side in the foaming direction of the molding material in the cavity.
According to the present invention, it is possible to smoothly cause the staying gas in the cavity to flow into the recesses by providing the recesses before the staying gas moves due to foaming of the molding material.

  According to the first aspect of the present invention, it is possible to satisfactorily mold a foam molded product while reducing the number of parts of the molding apparatus. According to the second invention, the staying gas in the cavity can smoothly flow into the recess.

It is a schematic perspective view of a shaping | molding apparatus. It is a front view of a 2nd type | mold (intermediate mold part). It is sectional drawing of a 2nd type | mold (intermediate mold part) and a cushion material. (A) is sectional drawing of a part of shaping | molding apparatus, (b) is sectional drawing of the shaping | molding apparatus part at the time of cushion material shaping | molding. It is the perspective view which looked at the vehicle seat from the lower part.

Hereinafter, embodiments for carrying out the present invention will be described with reference to FIGS. In each figure, a symbol F is attached to the front of the member, a symbol B is attached to the rear of the member, a symbol UP is provided above the member, and a symbol DW is provided below the member.
A molding apparatus 10 in FIG. 1 is an apparatus for molding a foam molded article, and includes a first mold 11, a second mold 12, and a cavity 14 (details of each member will be described later).
In the present embodiment, the vehicle seat cushion material 4P (an example of a foam molded product, which will be described in detail later) can be molded using the molding apparatus 10 described above (see FIG. 5). At this time, it is considered that the staying gas in the cavity 14 (air in the cavity or foaming gas generated at the time of foam molding) does not cause any chipping in the cushion material 4P (so that the cushion material 4P is molded well). The
In this type of apparatus configuration, it is desirable that the cushion material 4P can be molded well while reducing the number of parts of the molding apparatus 10 (for example, omitting a breathable material and a holder). Therefore, in this embodiment, the cushion material 4P is favorably molded while reducing the number of parts of the molding apparatus 10 by the configuration described later.

[Cushion material]
The cushion material 4P is a member that can elastically support an occupant with a seat outer shape, and can be formed of, for example, polyurethane foam (see FIGS. 3 to 5).
The cushion material 4P of the present embodiment is a member (substantially rectangular shape) used for the seat cushion 4, and includes a convex portion 4a, an inclined portion 4b, and an elastic member 4c.
The convex part 4a is a convex part extending in the front-rear direction of the seat, and can be formed in the center of the back surface side of the cushion material 4P (part where the passenger is seated exclusively). In the formation part of the convex part 4a, the thickness dimension of the cushion material 4P is enlarged, and the seating property is improved. Further, the inclined part 4b is an inclined part at the end (rear end) of the convex part 4a and continues to the rear end of the cushion material 4P. The elastic member 4c is a rear portion of the convex portion 4a (immediately before the inclined portion 4b) and can be integrated when the cushion material 4P is molded (described later).

[Molding equipment]
The molding apparatus 10 includes a first mold 11, a second mold 12 (a plurality of concave portions 30), and a cavity 14 (see FIGS. 1 and 2).
The first mold 11 and the second mold 12 are mold members that can be closed to each other, and a cavity 14 (a space portion that follows the outer shape of the cushion material 4P) is formed between the first mold 11 and the second mold 12. Is done.
The first mold 11 of the present embodiment is a substantially rectangular parallelepiped member and has a first recessed portion 21. The first recessed portion 21 is a portion (typically uneven) having a shape following the seating surface shape of the cushion material 4 </ b> P, and can be formed at the center of the first mold 11.

The second mold 12 is a substantially rectangular parallelepiped member that follows the first mold 11, and has a second recessed portion 22, an intermediate mold portion 16, and a plurality of recessed portions 30 (described later). The second recessed portion 22 can be formed at the center of the second mold 12.
The intermediate mold portion 16 is a substantially rectangular parallelepiped protruding portion and has a third recessed portion 23. The third recessed portion 23 is an uneven portion that follows the back surface shape (convex portion 4a and the like) of the back surface of the cushion material 4P, and can be formed at the center of the intermediate mold portion 16. An inclined portion (inclined surface 16a) corresponding to the inclined portion 4b is formed at the end (rear end) of the third recessed portion 23.
In the present embodiment, the intermediate mold portion 16 is protruded and disposed at the center of the second mold 12 (in the second recessed portion 22), and is closed to the first mold 11. In this way, the cavity 14 is formed by the first recess portion 21 and the third recess portion 23, and the peripheral portion of the cavity 14 is formed at the closing portion between the outer periphery of the first mold 11 and the second mold 12. Can do.

(Concave)
Each of the plurality of recessed portions 30 is a recessed portion that is not communicated with the outside of the molding apparatus 10 and can be opened in the cavity (see FIGS. 1 to 4. May be given a sign).
In the present embodiment, the plurality of concave portions 30 can be formed on the inclined surface 16a of the intermediate mold portion 16 (where gas in the cavity 14 stays as will be described later). Then, the plurality of concave portions 30 are formed in parallel in the longitudinal direction and the short direction of the intermediate mold portion 16 (inclined surface 16a) (in parallel so as to have a substantially rectangular shape when viewed from above).
At this time, the capacity of the plurality of recesses 30 as a whole can be set to a capacity that allows the staying gas in the cavity 14 to flow in, for example, by adjusting the number of formations of the plurality of recesses 30.

And in a present Example, the capacity | capacitance of each recessed part 30 can be narrowed by forming the several recessed part 30 (refer FIG. 4).
Here, the dimensions (depth dimension L1 and diameter dimension L2) of each recess 30 can be appropriately set according to the foaming pressure of the molding material and the capacity of the cavity 14. For example when molding a cushion member 4P for single-seater typically it is set the capacity of the cavity 14 to 25,000cm ² ~35,000cm ^2. At this time, 50 recesses 30 can be formed, and the depth dimension L1 of each recess 30 can be set to 3 mm to 8 mm, and the diameter dimension L2 can be set to 3 mm to 5 mm.
And by narrowing the capacity | capacitance of each recessed part 30, when gas stays around the recessed part 30 (when a gas pool generate | occur | produces), the chipping of the cushioning material 4P caused by the gas pool can be reduced as much as possible (for example, repair). Can be made to an unnecessary size).
Similarly, even if the molding material enters the concave portion 30, the convex shape of the cushioning material 4P caused by the molding material can be shortened as much as possible (for example, it can be made a size that does not require repair).

[Arrangement of molding equipment]
With reference to FIG. 1, the shaping | molding apparatus 10 is arrange | positioned in a work space. At this time, the first mold 11 is arranged to be inclined with respect to the floor surface while the first mold 11 (first recess portion 21) is directed toward the operator side.
Next, the second mold 12 is movable toward the first mold 11. In the present embodiment, both molds can be closed by rotating the second mold 12 around a shaft (not shown) with respect to the first mold 11. Then, by closing the second mold 12 with respect to the first mold 11, the cavity 14 is configured by the first recessed portion 21 and the third recessed portion 23 while the intermediate mold portion 16 is disposed at the center.
Thus, in the present embodiment, the one end side (inclined surface 16a) of the intermediate mold portion 16 is disposed upward while the molding apparatus 10 is disposed in an inclined shape. In this way, when the cushion material 4P is molded (described later), the staying gas in the cavity 14 moves toward the inclined surface 16a side (downstream in the firing direction) above the apparatus due to foaming pressure of the molding material, and the like. Become.
In the present embodiment, after the first mold 11 and the second mold 12 are opened, the cushion material 4P formed on the intermediate mold portion 16 is taken out. At this time, since the first mold 11 is inclined and the first recessed portion 21 is directed toward the operator, the cushion material 4P can be easily pulled out from the first mold 11 (the mold cutting operation can be performed smoothly).

[Cushion material molding work]
Referring to FIGS. 1, 2, and 4, after a molding material (liquid molten resin or the like) is injected into first recess 21, first mold 11 and second mold 12 are closed to form cavity 14. To do.
Then, the cushioning material 4P is formed by foaming the molding material in the cavity 14 while heating the molding apparatus. At this time, in this embodiment, a substantially rectangular elastic member 4c (made of resin) is disposed in front of the inclined surface 16a.
Then, the molding material foams upward from the lower part of the cavity 14, so that the staying gas in the cavity 14 is gradually pushed upward of the apparatus. The stagnant gas flows into the plurality of recesses 30 while wrapping around the elastic member 4c by the foaming pressure of the molding material, so that the stagnant gas is removed from the cavity 14 as much as possible. Thereby, foaming of the molding material in the cavity 14 proceeds smoothly, and the cushioning material 4P is molded well.

In the above-described configuration, due to the foaming pressure during molding, stagnant gas may not enter the plurality of recesses 30 or the molding material may enter the plurality of recesses 30 (FIG. 4B). reference).
At this time, in this embodiment, by forming the plurality of recesses 30, the size of each recess 30 can be reduced. For this reason, when the gas stays around the recess 30, the chipping of the cushion material 4P caused by the staying gas can be reduced as much as possible (for example, it can be made to a size that does not require repair).
Similarly, even if the molding material enters the concave portion 30, the convex shape of the cushion material 4P due to the penetration of the molding material can be shortened as much as possible (for example, it can be made to a size that does not require repair).
As described above, in the present embodiment, by forming the plurality of concave portions 30 (narrow), post-processing of the cushion material 4P (operation for adjusting the shape of the chipped portion or the convex shape) can be made almost unnecessary.

As described above, in this embodiment, a plurality of concave portions 30 are formed in the intermediate mold portion 16 so that the gas staying in the cavity 14 can flow in when the molding material is foamed. And the cushion material 4P can be shape | molded favorably by making the residence gas in the cavity 14 flow in into the some recessed part 30 (without using a breathable raw material or a discharge means).
At this time, in this embodiment, by forming the plurality of recesses 30, the size of each recess 30 can be reduced. Thereby, post-processing of the cushion material 4P (operation for adjusting the shape of the chipped portion or the convex shape) can be omitted, and the production process of the cushion material 4P can be simplified.
And according to the present Example, by providing the plurality of recesses 30 on the downstream side in the foaming direction of the molding material (the destination where the staying gas moves due to foaming of the molding material), the gas can smoothly flow into the recesses 30. Can do.
Therefore, according to the present embodiment, the cushion material 4P can be molded well while reducing the number of parts of the molding apparatus 10.

[Test example]
Hereinafter, although a present Example is demonstrated based on a test example, this invention is not limited to a test example.
In this test example, as Example 1 and Example 2, a vehicle seat cushion material (for single passenger) was molded. As the molding apparatus, a molding apparatus having the configuration shown in FIG. 1 was used. A total of 50 recesses 30 were arranged in parallel on the inclined surface (5 vertical × 10 horizontal), and the size of each recess 30 was set to φ5 mm and depth 5 mm.

In this test, raw materials described in [Table 1] were used as polyurethane raw materials.
Here, RC-1230W in [Table 1] is a polyol (manufactured by Sanyo Chemical Co., Ltd.), MAB-028 is a polyol (manufactured by Asahi Glass Co., Ltd.), and CEF-060 is an isocyanate (manufactured by Nippon Polyurethane Co., Ltd.).
And the cushioning material of Example 1 and Example 2 shown in [Table 2] was shape | molded by shape | molding on the foaming conditions shown in [Table 3].

[Results and discussion]
When the cushion materials of Example 1 and Example 2 were visually confirmed, there were almost no conspicuous chipped portions or convex shapes that required post-treatment. For example, in the cushion material of each example, a large chipping (diameter dimension φ10 mm, depth dimension of 10 mm or more) was not observed.
This is considered to be because the cushioning material was able to be satisfactorily created by the staying gas flowing into the plurality of recesses. Further, it is considered that by making each concave portion narrow, the chipped portion and the convex shape can be made as small as possible.
For this reason, according to the present Example, it turned out that a cushion material can be favorably shape | molded, reducing the number of parts of a shaping | molding apparatus by several recessed part.

The vehicle seat of the present embodiment is not limited to the above-described embodiment, and can take other various embodiments.
(1) In this embodiment, the example which forms the some recessed part 30 in the 2nd type | mold 12 (intermediate mold part 16) was demonstrated, However, A some recessed part can be formed in at least one of a 1st type | mold and a 2nd type | mold. . And the formation number and shape of a recessed part can be changed suitably. For example, a plurality of linear recesses can be formed in addition to a cylindrical shape or a rectangular shape (dot-like recesses). Further, the individual recesses can have different shapes and dimensions.

(2) In the present embodiment, the example in which the back surface side (non-exposed portion) of the cushion material 4P is formed at the location where the recess 30 is formed, but the location where the recess is formed can be changed as appropriate. For example, when the design portion (portion exposed to the outside) of the cushion material is formed at the recessed portion forming portion, it is desirable to make each recessed portion narrower than the non-exposed portion. In this embodiment, a plurality of recesses are formed on the inclined surface 16a (one location), but a plurality of recesses can be formed at a plurality of locations of the molding apparatus.
(3) In the present embodiment, the configuration of the second mold 12 provided with the intermediate mold portion 16 is exemplified, but the configuration of the second mold is appropriately changed according to the sheet configuration (for example, the intermediate mold portion 16 is omitted). You can).
(4) In the present embodiment, the cushion material 4P of the seat cushion 4 has been described as an example of a foam molded product, but the type of the foam molded product is not limited. For example, as a foam molded article, various seat constituent members such as the seat back 6 and a cushion material of a vehicle configuration can be exemplified. Moreover, the foamed resin used can use various foamed resins other than polyurethane.

4 Seat cushion 6 Seat back 4P Cushion material 4a Convex part 4b Inclined part 4c Elastic member 10 Molding device 11 First mold 12 Second mold 14 Cavity 16 Intermediate mold part 16a Inclined surface 21 First concave part 22 Second concave part 23 First Three recessed parts 30 Recessed parts

Claims (2)

A first mold, a second mold that can be closed to the first mold, and a cavity formed between the first mold and the second mold, and foaming the molding material in the cavity. In a molding apparatus for molding foam molded products such as cushion materials for vehicle seats,
At least one of the first mold and the second mold is provided with a plurality of recesses that are not in communication with the outside of the molding apparatus, and the gas that stays in the cavity when the molding material is foamed in the plurality of recesses Is a molding device that can flow in. The molding apparatus according to claim 1, wherein the plurality of recesses are provided on the downstream side in the foaming direction of the molding material in the cavity.

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