JP2018202672A - Molding tool for resin foam molding, and manufacturing method of sheet pad for vehicle using the molding tool - Google Patents
Molding tool for resin foam molding, and manufacturing method of sheet pad for vehicle using the molding tool Download PDFInfo
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- 229920005989 resin Polymers 0.000 title claims abstract description 34
- 239000011347 resin Substances 0.000 title claims abstract description 34
- 238000000465 moulding Methods 0.000 title claims abstract description 25
- 238000010097 foam moulding Methods 0.000 title claims abstract description 22
- 238000004519 manufacturing process Methods 0.000 title claims description 18
- 230000005291 magnetic effect Effects 0.000 claims abstract description 79
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims description 16
- 229920005830 Polyurethane Foam Polymers 0.000 claims description 16
- 239000011496 polyurethane foam Substances 0.000 claims description 16
- 239000006260 foam Substances 0.000 claims description 15
- 239000000463 material Substances 0.000 claims description 14
- 238000000034 method Methods 0.000 claims description 12
- 229910001172 neodymium magnet Inorganic materials 0.000 claims description 12
- 238000007493 shaping process Methods 0.000 claims description 7
- 239000002023 wood Substances 0.000 claims description 7
- 229920003023 plastic Polymers 0.000 claims description 5
- 239000004033 plastic Substances 0.000 claims description 5
- 239000004744 fabric Substances 0.000 claims description 4
- 238000005187 foaming Methods 0.000 claims description 3
- 239000002985 plastic film Substances 0.000 claims description 3
- 229920006255 plastic film Polymers 0.000 claims description 3
- 239000002131 composite material Substances 0.000 claims description 2
- 238000001179 sorption measurement Methods 0.000 abstract description 4
- 230000002708 enhancing effect Effects 0.000 abstract 1
- 239000003973 paint Substances 0.000 description 8
- 239000007921 spray Substances 0.000 description 4
- 230000000274 adsorptive effect Effects 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 238000011156 evaluation Methods 0.000 description 3
- 230000004907 flux Effects 0.000 description 3
- 239000000696 magnetic material Substances 0.000 description 3
- 239000004745 nonwoven fabric Substances 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- 239000002390 adhesive tape Substances 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000003595 mist Substances 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- -1 polypropylene Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 229920002635 polyurethane Polymers 0.000 description 2
- 239000004814 polyurethane Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 2
- 229920005992 thermoplastic resin Polymers 0.000 description 2
- 239000002759 woven fabric Substances 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 230000002159 abnormal effect Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 238000002386 leaching Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000011344 liquid material Substances 0.000 description 1
- 239000006247 magnetic powder Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920006267 polyester film Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 229910000938 samarium–cobalt magnet Inorganic materials 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
Landscapes
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Molding Of Porous Articles (AREA)
Abstract
Description
本発明はインサート部材が一体に成形された樹脂発泡成形体の製造工程で使用される成形型に関し、特に、キャビティの面に付設される永久磁石による、キャビティ内にセットされる磁性部を有するインサート部材の固定力が向上し得た成形型に関する。 The present invention relates to a mold used in a manufacturing process of a resin foam molded body in which an insert member is integrally molded, and in particular, an insert having a magnetic part set in a cavity by a permanent magnet attached to the surface of the cavity. The present invention relates to a mold that can improve the fixing force of members.
従来より、車両用シート等のクッション材として用いられるポリウレタン発泡成形体には、金属バネとの接触による異音防止、ウレタン樹脂の浸出防止、あるいは発泡成形体の補強等を図るために、成形型内に織布や不織布等の布帛からなるインサート部材を配置後、液状ウレタン樹脂を注入して発泡成形して、インサート部材とポリウレタン発泡成形体とを一体に成形する（すなわち、インサート部材が一体に成形されたポリウレタン発泡成形体を得る）ことが行われている。このようなインサート部材が一体に成形された樹脂発泡成形体の製造では、成形型のキャビティ内にセットしたインサート部材が樹脂の発泡成形の過程で移動することなくキャビティ内に固定されている必要がある。このため、通常、成形型のキャビティの面に永久磁石を付設する一方、インサート部材には磁性部を設けておき、キャビティにインサート部材をセットしたときに、永久磁石の磁気効果によってインサート部材の磁性部を吸着して、インサート部材が固定されるようにする方法が採られている。インサート部材に磁性部を設ける方法としては、例えば、インサート部材の所望箇所に板状の磁性体片を両面粘着テープで貼付する方法がある（特許文献１）。 Conventionally, polyurethane foam moldings used as cushioning materials for vehicle seats, etc. are molded molds to prevent abnormal noise due to contact with metal springs, prevent leaching of urethane resin, or reinforce foam moldings. After an insert member made of a fabric such as a woven fabric or a non-woven fabric is placed therein, a liquid urethane resin is injected and foamed to form the insert member and the polyurethane foam molded body integrally (that is, the insert member is integrally formed). Obtaining a molded polyurethane foam molding) has been carried out. In the manufacture of such a resin foam molded body in which the insert member is integrally molded, the insert member set in the mold cavity must be fixed in the cavity without moving in the process of resin foam molding. is there. For this reason, usually, a permanent magnet is attached to the cavity surface of the mold, while a magnetic portion is provided in the insert member, and when the insert member is set in the cavity, the magnetic effect of the insert member is set by the magnetic effect of the permanent magnet. A method is adopted in which the part is adsorbed so that the insert member is fixed. As a method of providing a magnetic part in an insert member, for example, there is a method of sticking a plate-like magnetic body piece to a desired portion of the insert member with a double-sided adhesive tape (Patent Document 1).
本発明は、上記の事情に鑑みて為されたものであり、その目的は、キャビティの面に付設する複数の永久磁石によるインサート部材の磁性部に作用する磁気効果（吸着力）が従来よりも大きく向上し得る樹脂発泡成形用成形型を提供することにある。 The present invention has been made in view of the above circumstances, and its purpose is that the magnetic effect (attraction force) acting on the magnetic portion of the insert member by the plurality of permanent magnets attached to the surface of the cavity is higher than in the past. The object is to provide a mold for resin foam molding which can be greatly improved.
本発明者らは、上記の課題を解決すべく鋭意研究した結果、キャビティの面に付設する複数の永久磁石を、そのＳ極の端面をキャビティ側に向けた第１磁石とそのＮ極の端面をキャビティ側に向けた第２磁石とで構成し、特に、第１磁石と第２磁石とを交互に繰り返して配置すると、複数の永久磁石によるインサート部材の磁性部に作用する磁気効果（吸着力）が大きく向上することを見出した。本発明はかかる知見に基づくものであり、その特徴は以下の通りである。 As a result of diligent research to solve the above problems, the present inventors have determined that a plurality of permanent magnets attached to the surface of the cavity are a first magnet with its south pole end face facing the cavity and its north pole end face. Is composed of a second magnet directed toward the cavity, and in particular, when the first magnet and the second magnet are alternately arranged repeatedly, a magnetic effect (adsorption force) acting on the magnetic portion of the insert member by a plurality of permanent magnets ) Was greatly improved. The present invention is based on such findings, and the features thereof are as follows.
［１］ インサート部材が一体に成形された樹脂発泡成形体の製造工程で使用される樹脂発泡成形用成形型であって、
成形型のキャビティの面にインサート部材が有する磁性部を吸着するための複数の永久磁石が付設され、
該複数の永久磁石は、そのＳ極の端面をキャビティ側に向けた第１磁石とそのＮ極の端面をキャビティ側に向けた第２磁石とからなることを特徴とする樹脂発泡成形用成形型。
［２］ 第１磁石と第２磁石が交互に繰り返し配置されている、上記［１］記載の成形型。
［３］ 隣接する第１磁石と第２磁石が離間している、上記［２］記載の成形型。
［４］ 隣接する第１磁石と第２磁石は互いの側面同士が接触している、上記［２］記載の成形型。
［５］ 複数の永久磁石の総数が４個以上である、上記［１］〜［４］のいずれか１つに記載の成形型。
［６］ 複数の永久磁石のそれぞれがネオジウム磁石である、上記［１］〜［５］のいずれか１つに記載の成形型。
［７］ 複数の永久磁石が成形型の上型のキャビティの内面に付設されている、上記［１］〜［６］のいずれか１つに記載の成形型。
［８］ インサート部材が、布帛、ウレタンスラブシート、ウレタンチップ、プラスチックフィルム、ウッドストック材料の成形体、及びウッドプラスチック材料の成形体からなる群から選択されるいずれか１種か、或いは、２種以上の複合体である、上記［１］〜［７］のいずれか１つに記載の成形型。
［９］ 上記［１］〜［８］のいずれか１つに記載の成形型のキャビティに磁性部を有するインサート部材をセットし、複数の永久磁石の磁気効果により該インサート部材の磁性部が吸着されて該インサート部材が固定される工程、
前記成形型のキャビティにウレタン発泡樹脂を注入して発泡させ、前記インサート部材と一体に成形されたポリウレタン発泡成形体を得る工程、及び
前記インサート部材と一体に成形されたポリウレタン発泡成形体を前記成形型から脱型する工程、を含むことを特徴とする、車両用シートパッドの製造方法。
[1] A resin foam molding die used in a manufacturing process of a resin foam molded body in which an insert member is integrally molded,
A plurality of permanent magnets are attached to the surface of the mold cavity to adsorb the magnetic part of the insert member,
The plurality of permanent magnets are composed of a first magnet with its S pole end face facing the cavity and a second magnet with its N pole end face facing the cavity. .
[2] The mold according to [1], wherein the first magnet and the second magnet are alternately and repeatedly arranged.
[3] The mold according to [2], wherein the adjacent first magnet and second magnet are separated from each other.
[4] The mold according to [2], wherein the side surfaces of the adjacent first magnet and second magnet are in contact with each other.
[5] The mold according to any one of [1] to [4], wherein the total number of the plurality of permanent magnets is four or more.
[6] The mold according to any one of [1] to [5], wherein each of the plurality of permanent magnets is a neodymium magnet.
[7] The mold according to any one of [1] to [6], wherein a plurality of permanent magnets are attached to the inner surface of the cavity of the upper mold of the mold.
[8] The insert member is one or two selected from the group consisting of a fabric, a urethane slab sheet, a urethane chip, a plastic film, a molded body of wood stock material, and a molded body of wood plastic material. The mold according to any one of the above [1] to [7], which is the above composite.
[9] An insert member having a magnetic part is set in the cavity of the mold according to any one of [1] to [8], and the magnetic part of the insert member is attracted by the magnetic effect of a plurality of permanent magnets. And the step of fixing the insert member,
Injecting urethane foam resin into the cavity of the mold and foaming to obtain a polyurethane foam molded body molded integrally with the insert member, and molding the polyurethane foam molded body molded integrally with the insert member A method for producing a vehicle seat pad comprising the step of demolding from a mold.
本発明の樹脂発泡成形用成形型によれば、キャビティの面に付設する複数の永久磁石によるインサート部材の磁性部に作用する磁気効果（吸着力）が従来よりも大きく向上する。このため、樹脂発泡成形過程でのインサート部材の移動を防止するために必要なインサート部材に設ける磁性部の数（例えば、インサート部材に貼付する磁性体片の数）を従来よりも減らすことができ、インサート部材が一体に成形された樹脂発泡成形体の製造コストを削減することができる。 According to the mold for resin foam molding of the present invention, the magnetic effect (adsorptive force) acting on the magnetic part of the insert member by the plurality of permanent magnets attached to the surface of the cavity is greatly improved as compared with the conventional one. For this reason, the number of magnetic parts provided in the insert member necessary for preventing the movement of the insert member during the resin foam molding process (for example, the number of magnetic body pieces to be affixed to the insert member) can be reduced as compared with the conventional case. The manufacturing cost of the resin foam molded body in which the insert member is integrally molded can be reduced.
また、従来は、磁性部に加え、キャビティの面に立設したピンが係止される穴部を形成して、固定することが必要であったインサート部材に対して、ピンと穴部の係止構造を必ずしも必要とせず、インサート部材に形成した磁性部に作用する吸着力のみで、インサート部材を固定することが可能となる。このため、製造現場での作業者のインサート部材のキャビティ内への配置作業が容易になり、インサート部材が一体に成形された樹脂発泡成形体の製造効率が向上する。 Conventionally, in addition to the magnetic part, the pin and the hole are locked to the insert member that has been required to form and fix the hole that locks the pin standing on the cavity surface. A structure is not necessarily required, and it is possible to fix the insert member only with an attractive force acting on the magnetic portion formed on the insert member. For this reason, the worker can easily arrange the insert member in the cavity at the manufacturing site, and the manufacturing efficiency of the resin foam molded body in which the insert member is integrally molded is improved.
以下、本発明をその好適な実施形態に即してより詳しく説明する。
図１は本発明の第１例の樹脂発泡成形用成形型（以下、単に「成形型」とも略称する）の断面を模式的に示した図であり、図において、１Ａ−１は上型、１Ｂは下型、２は永久磁石、３はキャビティ、１０は成形型を示す。なお、図１は成形型における発泡樹脂の流路であるスプール、ランナー及びゲートのうち、キャビティ３の直前のゲートのみを示し、スプール、ランナー等は省略している。
Hereinafter, the present invention will be described in more detail with reference to preferred embodiments thereof.
FIG. 1 is a diagram schematically showing a cross section of a molding die for resin foam molding (hereinafter simply referred to as “molding die”) of a first example of the present invention, in which 1A-1 is an upper die, 1B is a lower mold, 2 is a permanent magnet, 3 is a cavity, and 10 is a mold. FIG. 1 shows only the gate immediately before the cavity 3 among the spool, runner, and gate which are the flow paths of the foamed resin in the mold, and the spool, runner and the like are omitted.
図２は本発明の第２例の成形型の上型の断面を模式的に示した図であり、図において、図１と同一符号は同一また相当する部分を示す。該第２例の成形型１１の下型は第１例のそれと同じであるので、図示を省略し、上型１Ａ−２のみを示している。 FIG. 2 is a diagram schematically showing a cross section of the upper mold of the molding die of the second example of the present invention, in which the same reference numerals as those in FIG. 1 denote the same or corresponding parts. Since the lower mold of the mold 11 of the second example is the same as that of the first example, the illustration is omitted and only the upper mold 1A-2 is shown.
本発明の樹脂発泡成形用の成形型は、インサート部材と一体に成形された樹脂発泡成形体を製造する際に使用する成形型であり、第１例及び第２例の成形型１０、１１に示されるように、キャビティ３の面（すなわち、キャビティを区画している壁面）に付設される複数の永久磁石２が、そのＳ極の端面をキャビティ３側に向けた第１磁石２ＡとそのＮ極の端面をキャビティ３側に向けた第２磁石２Ｂとから構成されていることが特徴である。 The mold for resin foam molding of the present invention is a mold used when manufacturing a resin foam molded body integrally formed with an insert member. In the molds 10 and 11 of the first and second examples, As shown, the plurality of permanent magnets 2 attached to the surface of the cavity 3 (that is, the wall surface defining the cavity) are the first magnet 2A and the N thereof whose end face of the south pole faces the cavity 3 side. It is characterized by being composed of a second magnet 2B with the pole end face facing the cavity 3 side.
通常、複数の永久磁石２は、図１、２に示されるように、第１磁石２Ａと第２磁石２Ｂが交互に繰り返された配置とする。すなわち、異極並列（Ｎ極-Ｓ極）の繰り返しの構成とする。 Usually, the plurality of permanent magnets 2 are arranged such that the first magnet 2A and the second magnet 2B are alternately repeated as shown in FIGS. That is, it is set as the structure which repeats different polarity parallel (N pole-S pole).
図４は従来の成形型の上型の断面を模式的に示した図であり、図１と同一符号は同一また相当する部分を示す。かかる従来の成形型２０の下型は本発明の第１例の成形型１０（図１）のそれと同じであるので、図示を省略し、上型２１のみを示している。上型２１には図１の成形型１０の上型１Ａ−１と同数の永久磁石２がキャビティ３の面に付設されているが、全ての永久磁石２がＳ極の端面をキャビティ３側に向けて付設されている（すなわち、複数の永久磁石２は同極並列（Ｓ極−Ｓ極）で配置されている）。なお、複数の永久磁石２が同極並列で配置される場合、キャビティ３側に向ける磁石の端面がＮ極であってＳ極であっても、インサート部材の磁性部に作用する吸着力は同じである。 FIG. 4 is a view schematically showing a cross section of an upper mold of a conventional molding die. The same reference numerals as those in FIG. 1 denote the same or corresponding parts. Since the lower mold of the conventional mold 20 is the same as that of the mold 10 (FIG. 1) of the first example of the present invention, the illustration is omitted and only the upper mold 21 is shown. The same number of permanent magnets 2 as the upper mold 1A-1 of the mold 10 in FIG. 1 are attached to the surface of the cavity 3, but all the permanent magnets 2 have the end face of the S pole facing the cavity 3 side. (I.e., the plurality of permanent magnets 2 are arranged in parallel with the same polarity (S pole-S pole)). When a plurality of permanent magnets 2 are arranged in parallel with each other, even if the end face of the magnet directed toward the cavity 3 is N-pole and S-pole, the attractive force acting on the magnetic part of the insert member is the same. It is.
後述の評価試験から明らかなように、図１及び図２示される本発明の成形型１０、１１では、キャビティ３の面に付設される複数の永久磁石２（２Ａ、２Ｂ）が異極並列（Ｎ極-Ｓ極）の繰り返しの構成であることから、図４の成形型２０のようなキャビティ３の面に付設される複数の永久磁石２が同極並列（Ｓ極−Ｓ極）で配置された成形型に比べて、複数の永久磁石２によるインサート部材の磁性部に作用する磁気効果（吸着力）が増大する。この磁気効果（吸着力）が増大する理由は明らかではないが、２つの永久磁石が異極並列すると、並列するＮ極からＳ極へ向う高密度の磁束分布が得られ、異極並列（Ｎ極-Ｓ極）の繰り返しによって高密度の磁束分布が連なった状態になり、この状態がインサート部材の磁性部に対する吸着力の向上に関与すると推察される。 As will be apparent from the evaluation test described later, in the molds 10 and 11 of the present invention shown in FIGS. 1 and 2, a plurality of permanent magnets 2 (2A and 2B) attached to the surface of the cavity 3 are arranged in parallel with different poles ( N pole-S pole), the plurality of permanent magnets 2 attached to the surface of the cavity 3 like the mold 20 in FIG. 4 are arranged in parallel with each other (S pole-S pole). Compared to the formed mold, the magnetic effect (attraction force) acting on the magnetic part of the insert member by the plurality of permanent magnets 2 is increased. The reason why this magnetic effect (attraction force) increases is not clear, but when two permanent magnets are arranged in parallel with different poles, a high-density magnetic flux distribution from the parallel N pole to the S pole is obtained, and the different pole parallel (N It is presumed that the high-density magnetic flux distribution is connected by repetition of the pole-S pole), and this state is related to the improvement of the attractive force with respect to the magnetic part of the insert member.
本発明の成形型において、キャビティ３の面に付設される複数の永久磁石２（２Ａ、２Ｂ）の総数は、高い磁気効果（吸着力）を得るためには、通常、４個以上である。一方、永久磁石２（２Ａ、２Ｂ）の総数の上限は特に限定されず、キャビティの大きさ、キャビティにセットされるインサート部材の大きさ、インサート部材の重量等を考慮して適宜決定され、特に限定はされないが、通常、２０個程度である。 In the mold of the present invention, the total number of the plurality of permanent magnets 2 (2A, 2B) attached to the surface of the cavity 3 is usually 4 or more in order to obtain a high magnetic effect (adsorption force). On the other hand, the upper limit of the total number of permanent magnets 2 (2A, 2B) is not particularly limited, and is appropriately determined in consideration of the size of the cavity, the size of the insert member set in the cavity, the weight of the insert member, etc. Although not limited, it is usually about 20 pieces.
永久磁石２（第１磁石２Ａ及び第２磁石２Ｂ）の種類は特に限定されず、例えば、ネオジム磁石、サマリウムコバルト磁石、フェライト磁石、ネオジム磁石等が利用可能であるが、最も磁力が大きく高磁場を発生することができるネオジム磁石が好ましい。また、永久磁石２（２Ａ、２Ｂ）の形状は特に限定されないが、通常は、角柱、円柱、楕円柱等の柱状物であり、柱状物の高さと断面の長さ（断面径）との関係も特に限定されず、高さが断面の長さ（断面径）より大きいものであっても、小さいものであっても良いが、付設のしやすさ等の観点から、高さが断面の長さ（断面径）より大きいものが好ましい。 The type of the permanent magnet 2 (the first magnet 2A and the second magnet 2B) is not particularly limited. For example, a neodymium magnet, a samarium cobalt magnet, a ferrite magnet, a neodymium magnet, or the like can be used. Neodymium magnets capable of generating The shape of the permanent magnet 2 (2A, 2B) is not particularly limited, but is usually a columnar object such as a prism, cylinder, or elliptical column, and the relationship between the height of the columnar and the length of the cross section (cross section diameter). Is not particularly limited, and the height may be larger or smaller than the length of the cross section (cross section diameter), but from the viewpoint of ease of attachment, the height is the length of the cross section. Those larger than the thickness (cross-sectional diameter) are preferable.
なお、図１、図２の成形型１０、１１では、永久磁石２（第１磁石２Ａ）のＳ極の端面及び永久磁石２（第２磁石２Ｂ）のＮ極の端面がキャビティ３の面と同一平面内に位置するように、永久磁石２を上型１−Ａに埋設しているが、第１磁石２ＡのＳ極の端面と第２磁石２ＢのＮ極の端面が同一平面内に位置するのであれば、第１磁石２ＡのＳ極の端面と第２磁石２ＢのＮ極の端面がキャビティ３の面よりも突出していてもよい。 1 and 2, the S pole end surface of the permanent magnet 2 (first magnet 2A) and the N pole end surface of the permanent magnet 2 (second magnet 2B) are the surfaces of the cavity 3. The permanent magnet 2 is embedded in the upper mold 1-A so as to be located in the same plane, but the end face of the S pole of the first magnet 2A and the end face of the N pole of the second magnet 2B are located in the same plane. If so, the end face of the S pole of the first magnet 2 </ b> A and the end face of the N pole of the second magnet 2 </ b> B may protrude from the face of the cavity 3.
また、図１の成形型１０では、異極並列の隣接する第１磁石２Ａと第２磁石２Ｂが離間しているが、図２の成形型１１に示されるように、異極並列の隣接する第１磁石２Ａと第２磁石２Ｂは互いの側面同士が接触した状態であってもよい。なお、一個の永久磁石２の幅（異極並列の隣接する第１磁石２Ａと第２磁石２Ｂのそれぞれの幅）は特に限定はされないが、例えば、永久磁石が柱状物である場合、その幅（断面の長さ（断面径））は、付設する磁石の安定性の観点から８〜２０ｍｍ程度が好ましい。また、異極並列の隣接する第１磁石２Ａと第２磁石２Ｂが離間している場合、その離間距離は２０ｍｍ以下が好ましく、１０ｍｍ以下がより好ましく、５ｍｍ以下が特に好ましい。離間距離が２０ｍｍを超えると、異極並列（Ｎ極-Ｓ極）及び異極並列の繰り返しによる、インサート部材の磁性部に作用する磁気効果（吸着力）の増大効果が得られにくくなる。 Further, in the mold 10 of FIG. 1, the adjacent first magnet 2A and the second magnet 2B in parallel with different polarities are separated from each other. However, as shown in the mold 11 in FIG. The first magnet 2A and the second magnet 2B may be in a state where their side surfaces are in contact with each other. The width of each permanent magnet 2 (the widths of the adjacent first magnet 2A and second magnet 2B adjacent in different polarities) is not particularly limited. For example, when the permanent magnet is a columnar object, the width The length of the cross section (cross section diameter) is preferably about 8 to 20 mm from the viewpoint of the stability of the attached magnet. Further, when the adjacent first magnet 2A and second magnet 2B in parallel with different polarities are separated from each other, the distance is preferably 20 mm or less, more preferably 10 mm or less, and particularly preferably 5 mm or less. When the separation distance exceeds 20 mm, it is difficult to obtain an effect of increasing the magnetic effect (adsorptive force) acting on the magnetic portion of the insert member by repeating different polar parallels (N pole-S pole) and different polar parallels.
図３は本発明の第３例の成形型の上型の断面を模式的に示した図であり、磁性部が永久磁石に吸着されたインサート部材も図示している。図において、図１と同一符号は同一また相当する部分を示し、５はインサート部材、５Ａは不織布、５Ｂはウレタンチップ、６は磁性部（インサート部材に貼付された磁性体片）、１２は成形型を示す。該第３例の成形型１２の下型は第１例のそれと同じであるので、図示を省略し、上型１Ａ−３のみを示している。 FIG. 3 is a view schematically showing a cross section of the upper mold of the molding die of the third example of the present invention, and also shows an insert member in which a magnetic part is adsorbed by a permanent magnet. In the figure, the same reference numerals as those in FIG. 1 denote the same or corresponding parts, 5 is an insert member, 5A is a non-woven fabric, 5B is a urethane chip, 6 is a magnetic part (a magnetic piece affixed to the insert member), and 12 is molded. Indicates the type. Since the lower mold of the mold 12 of the third example is the same as that of the first example, the illustration is omitted and only the upper mold 1A-3 is shown.
該第３例の成形型１２は、第１磁石２Ａと第２磁石２Ｂが互いの側面同士が接触した状態で交互に繰り返し配置された磁石配列２−１を、キャビティの面の２箇所に付設している。すなわち、本発明の成形型において、第１磁石２Ａと第２磁石２Ｂが互いの側面同士が接触した状態で交互に繰り返し配置された磁石配列２−１はキャビティの面の複数箇所に設けることができる。 In the mold 12 of the third example, the magnet array 2-1 in which the first magnet 2A and the second magnet 2B are alternately and repeatedly arranged with their side surfaces in contact with each other is provided at two locations on the cavity surface. doing. That is, in the molding die of the present invention, the magnet array 2-1 in which the first magnet 2A and the second magnet 2B are alternately and repeatedly arranged with their side surfaces in contact with each other may be provided at a plurality of locations on the cavity surface. it can.
本発明の成形型において、通常、複数の永久磁石２は成形型の上型のキャビティの面に付設される。これは、通常、上型のキャビティ（キャビティにおける上型の空間）にインサート部材をセットし、下型のキャビティ（キャビティにおける下型の空間）に樹脂発泡成形体を得るための発泡樹脂を流入して、発泡成形を行うためである。なお、「上型」及び「下型」は、鉛直方向の上方側に位置させる型が「上型」、下方側に位置させる型が「下型」である。 In the mold according to the present invention, the plurality of permanent magnets 2 are usually attached to the surface of the cavity of the upper mold of the mold. This is usually done by setting an insert member in the upper mold cavity (the upper mold space in the cavity) and injecting the foam resin to obtain the resin foam molding into the lower mold cavity (lower mold space in the cavity). This is because foam molding is performed. The “upper mold” and the “lower mold” are the “upper mold” that is positioned on the upper side in the vertical direction and the “lower mold” that is positioned on the lower side.
成形型（上型及び下型）の材質に特に制限はなく、一般的な樹脂発泡成形用の成形型と同様のアルミニウムや鋳物製の型でよい。 The material of the mold (upper mold and lower mold) is not particularly limited, and may be a mold made of aluminum or a casting similar to a general mold for resin foam molding.
本発明の成形型のキャビティに磁性部を有するインサート部材をセットすると、複数の永久磁石により、インサート部材の磁性部へ強力な吸着力が作用し、インサート部材が成形型内に強固に固定される。そして、このインサート部材が強固に固定された状態で、キャビティ内に、例えば、ウレタン発泡樹脂を注入して発泡させ、インサート部材と一体に成形されたポリウレタン発泡成形体を得、このインサート部材と一体に成形されたポリウレタン発泡成形体を成形型から脱型することで、車両用シートパッドが製造される。 When an insert member having a magnetic part is set in the cavity of the mold according to the present invention, a strong attracting force acts on the magnetic part of the insert member by a plurality of permanent magnets, and the insert member is firmly fixed in the mold. . Then, in a state where the insert member is firmly fixed, for example, urethane foam resin is injected into the cavity and foamed to obtain a polyurethane foam molded body integrally formed with the insert member. The vehicle seat pad is manufactured by removing the molded polyurethane foam from the mold.
本発明の成形型にて、樹脂発泡成形体と一体成形されるインサート部材としては、例えば、車両用シートのクッション材であるポリウレタン発泡成形体と一体に成形されて、ポリウレタン発泡成形体の裏面に接合される、不織布、織布等の布帛（繊維系素材）が挙げられる。また、かかるポリウレタン発泡成形体の非意匠面に接合される、ポリウレタン、ポリプロピレン（ＰＰ）、ポリエチレン（ＰＥ）等のプラスチックからなる直方体、立方体等の多面体等の立体形状に成形された中実成形体；ウレタンチップ；ウッドストック材料やウッドプラスチック材料からなる直方体、立方体等の多面体等の立体形状に成形された中実成形体；多孔性または非多孔性のプラスチックフィルム（例えば、ポリエステルフィルム、ポリオレフィンフィルム、ポリアミドフィルム、ポリ塩化ビニルフィルム、ポリスチレンフィルム、ウレタンスラブシート等）等が挙げられる。また、以上例示したものから選択される２種以上の複合体が挙げられる。なお、上記「ウレタンチップ」とはポリウレタン発泡体（発泡ポリウレタン）の廃材を押し固めたものを指し、「ウレタンスラブシート」とは、ポリウレタン発泡体をフィルム（シート）にスライスしたものを指す。 As an insert member integrally molded with the resin foam molded body in the molding die of the present invention, for example, it is molded integrally with a polyurethane foam molded body which is a cushion material for a vehicle seat, and is formed on the back surface of the polyurethane foam molded body. Examples of the fabric (fiber material) such as a nonwoven fabric and a woven fabric to be joined. In addition, a solid molded body formed into a three-dimensional shape such as a rectangular parallelepiped made of plastic such as polyurethane, polypropylene (PP), polyethylene (PE), or a polyhedron such as a cube, which is joined to the non-design surface of the polyurethane foam molded body. A solid chip formed into a three-dimensional shape such as a rectangular parallelepiped made of wood stock material or wood plastic material, a cube, or the like; a porous or non-porous plastic film (for example, a polyester film, a polyolefin film, Polyamide film, polyvinyl chloride film, polystyrene film, urethane slab sheet, etc.). Moreover, the 2 or more types of composite_body | complex selected from what was illustrated above is mentioned. The above “urethane chip” refers to a polyurethane foam (foamed polyurethane) waste material pressed and solidified, and the “urethane slab sheet” refers to a polyurethane foam sliced into a film (sheet).
インサート部材への磁性部の形成は従来公知の方法で行えばよい。例えば、（ａ）磁性体片を両面粘着テープで貼付する方法、（ｂ）熱可塑性樹脂及び磁性体を含む熱可塑性樹脂磁性物や硬化性バインダに磁性体粉末を分散させた磁性材料を含浸・固化（硬化）させる方法等が挙げられる。また、エアー式スプレーガン等の液状物を霧状にして噴射する手段を使用して、市販の磁性塗料をインサート部材の表面に霧状にして吹付けて自然乾燥させて、磁性塗料の付着固化物からなる磁性部を形成する方法が挙げられる。この方法であれば、特に非多孔性の部材や比較的空隙が少ない（密度が大きい）多孔性部材の表面に簡単に磁性部を形成することができる。 The magnetic part may be formed on the insert member by a conventionally known method. For example, (a) a method of sticking a magnetic piece with a double-sided adhesive tape, (b) impregnating a thermoplastic resin magnetic material containing a thermoplastic resin and a magnetic material, or a magnetic material in which a magnetic powder is dispersed in a curable binder. Examples thereof include a method of solidifying (curing). Also, using a means to spray liquid material such as an air spray gun in the form of a mist, commercially available magnetic paint is sprayed on the surface of the insert member and sprayed naturally to solidify and solidify the magnetic paint. The method of forming the magnetic part which consists of a thing is mentioned. With this method, it is possible to easily form a magnetic part particularly on the surface of a non-porous member or a porous member having relatively little voids (high density).
本発明の成形型を使用すれば、キャビティの面に付設する複数の永久磁石によるインサート部材の磁性部に作用する磁気効果（吸着力）が従来よりも大きく向上する。このため、例えば、樹脂発泡成形過程でのインサート部材の移動を防止するために必要なインサート部材に設ける磁性部の数（例えば、インサート部材に貼付する磁性体片の数）を従来よりも減らすことができ、インサート部材が一体に成形された樹脂発泡成形体の製造コストを削減することができる。 If the molding die of the present invention is used, the magnetic effect (adsorptive force) acting on the magnetic part of the insert member by the plurality of permanent magnets attached to the surface of the cavity is greatly improved as compared with the prior art. For this reason, for example, the number of magnetic parts provided in the insert member necessary for preventing the movement of the insert member in the resin foam molding process (for example, the number of magnetic pieces to be affixed to the insert member) is reduced as compared with the conventional case. Thus, the manufacturing cost of the resin foam molded body in which the insert member is integrally molded can be reduced.
また、従来は、磁性部に加え、キャビティの面に立設したピンが係止される穴部を形成して、固定することが必要であった、ウレタンチップやウッドストックの成形体のような高重量の部材であっても、インサート部材に形成した磁性部に作用する吸着力のみで、インサート部材を型内に固定することができる。よって、製造現場の作業者が、インサート部材を型内に配置する際に、型の内面に立設されたピンをインサート部材に形成した穴部に挿入する作業が不要になり、作業者のインサート部材の型内への配置作業が容易かつ短時間で行える。 Conventionally, in addition to the magnetic part, it was necessary to form and fix a hole part to which a pin standing on the surface of the cavity is locked, such as a molded article of urethane chip or wood stock. Even if it is a heavy member, the insert member can be fixed in the mold only by the attractive force acting on the magnetic part formed on the insert member. Therefore, when the worker on the manufacturing site arranges the insert member in the mold, it is not necessary to insert the pin erected on the inner surface of the mold into the hole formed in the insert member. The work of placing the members in the mold can be performed easily and in a short time.
また、ピンと穴部の係止構造を必ずしも必要とせず、インサート部材に形成した磁性部に作用する吸着力のみで、インサート部材を固定することが可能となる。このため、製造現場での作業者のインサート部材の成形型キャビティ内への配置作業が容易になり、インサート部材が一体に成形された樹脂発泡成形体の製造効率が向上する。 In addition, the pin and hole locking structure is not necessarily required, and it is possible to fix the insert member only by the attraction force acting on the magnetic part formed on the insert member. For this reason, the worker can easily place the insert member in the molding die cavity at the manufacturing site, and the manufacturing efficiency of the resin foam molded body in which the insert member is integrally molded is improved.
本発明の成形型は、特に、車両用シートパッドの製造に好適に使用することができる。
すなわち、本発明は、上述の成形型のキャビティに磁性部を有するインサート部材をセットし、複数の永久磁石の磁気効果により該インサート部材の磁性部が吸着されて該インサート部材が固定される工程、
成形型のキャビティにウレタン発泡樹脂を注入して発泡させ、インサート部材と一体に成形されたポリウレタン発泡成形体を得る工程、及び
インサート部材と一体に成形されたポリウレタン発泡成形体を成形型から脱型する工程、を含む、車両用シートパッドの製造方法も提供する。
The mold of the present invention can be suitably used particularly for the production of a vehicle seat pad.
That is, the present invention is a process in which an insert member having a magnetic part is set in the cavity of the mold described above, and the magnetic part of the insert member is attracted by the magnetic effect of a plurality of permanent magnets, and the insert member is fixed.
Injecting urethane foam resin into the cavity of the mold and foaming it to obtain a polyurethane foam molded body molded integrally with the insert member, and removing the polyurethane foam molded body molded integrally with the insert member from the mold The manufacturing method of the vehicle seat pad including the process to perform is also provided.
以下、実施例を示して、本発明をより具体的に説明するが、本発明は以下の実施例によって制限を受けるものではなく、上記・下記の趣旨に適合し得る範囲で適当に変更を加えて実施することも勿論可能であり、それらはいずれも本発明の技術的範囲に包含される。 EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples. However, the present invention is not limited by the following examples, and appropriate modifications are made within a range that can meet the above and the following purposes. Of course, it is also possible to implement them, and they are all included in the technical scope of the present invention.
［実施例１］
プラスチック製の平面形状が長方形の板材（短辺２００ｍｍ、長辺３５０ｍｍ、厚さ８ｍｍ）１枚と、断面の直径が８ｍｍ、高さが１０ｍｍの円柱状のネオジウム磁石５個を用意し、板材の片面の短手方向の中間位置に、長辺と平行方向に５個の円柱状のネオジウム磁石を、Ｎ極を上に向けた磁石と、Ｓ極を上に向けた磁石とが交互になり、かつ、隣接する磁石の側面同士が接触する状態に一例に並べて載置し、図２の成形型１１の上型１Ａ−２のモデルである上型モデルＡを組み立てた。
[Example 1]
Prepare a plate of rectangular plastic plate (short side 200 mm, long side 350 mm, thickness 8 mm) and five cylindrical neodymium magnets with a cross-sectional diameter of 8 mm and a height of 10 mm. In the middle position in the short direction on one side, five columnar neodymium magnets parallel to the long side, the magnets with the N pole facing up, and the magnets with the S pole facing up are alternated, And it mounted in an example in the state which the side surfaces of adjacent magnets contact, and the upper mold | type A which is a model of the upper mold | type 1A-2 of the shaping | molding die 11 of FIG. 2 was assembled.
［比較例１］
上記と同様の板材及び５個の円柱状のネオジウム磁石を使用し、板材の片面の短手方向の中間位置に、長辺と平行方向に５個の円柱状のネオジウム磁石を全てＮ極を上に向けて、８ｍｍ間隔で一例に並べて載置し、図４の成形型２０の上型２１のモデルである上型モデルＢを組み立てた。
[Comparative Example 1]
Using the same plate material and 5 columnar neodymium magnets as above, all the 5 columnar neodymium magnets in the direction parallel to the long side are all N poles up in the middle position in the short direction of one side of the plate material. The upper model B, which is a model of the upper mold 21 of the mold 20 in FIG. 4, was assembled.
［参考例１］
上記と同様の板材及び５個の円柱状のネオジウム磁石を使用し、板材の片面の短手方向の中間位置に、長辺と平行方向に５個の円柱状のネオジウム磁石をＮ極を上に向けた磁石と、Ｓ極を上に向けた磁石とが交互になり、かつ、隣接する磁石が３０ｍｍ離間する状態に一例に並べて載置し、上型モデルＣを組み立てた。
[Reference Example 1]
Using the same plate material and five columnar neodymium magnets as above, five columnar neodymium magnets with the N pole on the middle of the short side of one side of the plate material in the direction parallel to the long side The upper model C was assembled by alternately placing the magnets facing each other and the magnets having the S poles facing upward, and adjacent magnets being 30 mm apart.
［評価試験］
（磁性部付きインサート部材の作製）
インサート部材として、図５に示す、直方体（W×H×D＝150mm×10mm×45mm）形状のウレタンチップ（密度：118.5kg/m3）５０を用意し、磁性塗料を霧状に噴射する手段としてエアー式スプレーガンを使用し、ウレタンチップの主面（W×D＝150mm×45 mm）に、エアー式スプレーガンを移動させながら磁性塗料（「マグネットペイント」（ターナー色彩株式会社製））を吹き付けて乾燥させ、磁性塗料（固化物）の付着物からなる、線幅が約３９ｍｍ、線の全長が１５０ｍｍの線パターンの磁性部（磁性塗料の固化物の総付着量：１６５０ｍｇ、単位面積（１ｍｍ２）当たりの磁性塗料の固化物の付着量：０．３１４ｍｇ／ｍｍ２）５１を形成して、磁性部付きインサート部材５２を作製した。
[Evaluation test]
(Production of insert member with magnetic part)
As the insert member, a rectangular parallelepiped (W × H × D = 150 mm × 10 mm × 45 mm) -shaped urethane tip (density: 118.5 kg / m 3 ) 50 shown in FIG. 5 is prepared and means for spraying magnetic paint in a mist form Use an air spray gun as a magnetic paint ("Magnet Paint" (Turner Color Co., Ltd.)) while moving the air spray gun to the main surface of the urethane tip (W x D = 150 mm x 45 mm). Sprayed and dried to form a magnetic part of a line pattern having a line width of about 39 mm and a total length of the line of 150 mm, consisting of deposits of magnetic paint (solidified material) (total amount of solidified magnetic paint: 1650 mg, unit area ( Amount of solidified magnetic paint per 1 mm 2 ): 0.314 mg / mm 2 ) 51 was formed to produce an insert member 52 with a magnetic part.
（吸着性評価）
実施例１の上型モデルＡ、比較例１の上型モデルＢ及び参考例１の上型モデルＣのそれぞれについて、ネオジウム磁石の配列に上記作製した磁性部付きインサート部材の線パターンの磁性部を接触させて、磁性部付きインサート部材の吸着性を評価したところ、上型モデルＡ〜Ｃのいずれも、磁性部付きインサート部材を吸着し、その吸着状態が維持された。
(Adsorbability evaluation)
For each of the upper model A of the first example, the upper model B of the comparative example 1, and the upper model C of the reference example 1, the magnetic part of the line pattern of the insert member with the magnetic part prepared above is arranged in the arrangement of neodymium magnets. When it was made to contact and the adsorptivity of the insert member with a magnetic part was evaluated, all of upper model A-C adsorb | sucked the insert member with a magnetic part, and the adsorption state was maintained.
磁性部付きインサート部材が吸着状態の上型モデルＡ〜Ｃについて、それぞれ、上型モデルを作業台上に起立状態（板材の長軸が作業台表面に垂直な状態）に保持した後、自然転倒させる衝撃負荷試験を行ったところ、上型モデルＡには磁性部付きインサート部材が吸着した状態のままであったが、上型モデルＢ及び上型モデルＣからは磁性部付きインサート部材が離脱した。 For the upper mold models A to C with the magnetic part inserted, the upper mold model is held upright on the workbench (the long axis of the plate is perpendicular to the workbench surface), and then falls naturally. When the impact load test was performed, the insert member with a magnetic part remained adsorbed on the upper model A, but the insert member with a magnetic part was detached from the upper model B and the upper model C. .
この結果から、成形型のキャビティの面に付設する複数の永久磁石が、異極並列の繰り返しの配置であって、異極並列する２つの磁石が一方の磁石のＮ極から他方の磁石のＳ極へ向かう磁束分布が形成される近接状態にあることにより、インサート部材の磁性部に作用する磁気効果（吸着力）が増大することが明らかである。 From this result, the plurality of permanent magnets attached to the surface of the cavity of the molding die are repeatedly arranged in parallel with different polarities, and two magnets in parallel with different polarities are changed from the N pole of one magnet to the S of the other magnet. It is clear that the magnetic effect (attraction force) acting on the magnetic part of the insert member is increased by being in the proximity state in which the magnetic flux distribution toward the pole is formed.
１Ａ−１、１Ａ−２、１Ａ−３ 上型
１Ｂ 下型
２ 永久磁石
２Ａ 第１磁石
２Ｂ 第２磁石
３ キャビティ
５ インサート部材
６ 磁性部
１０、１１、１２、２０ 成形型
1A-1, 1A-2, 1A-3 Upper mold 1B Lower mold 2 Permanent magnet 2A First magnet 2B Second magnet 3 Cavity 5 Insert member 6 Magnetic part 10, 11, 12, 20 Mold
Claims (9)
成形型のキャビティの面にインサート部材が有する磁性部を吸着するための複数の永久磁石が付設され、
該複数の永久磁石は、そのＳ極の端面をキャビティ側に向けた第１磁石とそのＮ極の端面をキャビティ側に向けた第２磁石とからなることを特徴とする樹脂発泡成形用成形型。 A mold for resin foam molding used in a manufacturing process of a resin foam molded body in which an insert member is integrally molded,
A plurality of permanent magnets are attached to the surface of the mold cavity to adsorb the magnetic part of the insert member,
The plurality of permanent magnets are composed of a first magnet with its S pole end face facing the cavity and a second magnet with its N pole end face facing the cavity. .
前記成形型のキャビティにウレタン発泡樹脂を注入して発泡させ、前記インサート部材と一体に成形されたポリウレタン発泡成形体を得る工程、及び
前記インサート部材と一体に成形されたポリウレタン発泡成形体を前記成形型から脱型する工程、を含むことを特徴とする、車両用シートパッドの製造方法。 An insert member having a magnetic part is set in the cavity of the mold according to any one of claims 1 to 8, and the magnetic part of the insert member is attracted by a magnetic effect of a plurality of permanent magnets, and the insert member is fixed. Process
Injecting urethane foam resin into the cavity of the mold and foaming to obtain a polyurethane foam molded body molded integrally with the insert member, and molding the polyurethane foam molded body molded integrally with the insert member A method for producing a vehicle seat pad comprising the step of demolding from a mold.
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| JP2001252930A (en) * | 2000-03-10 | 2001-09-18 | Bridgestone Corp | Method for manufacturing foamed resin molded article |
| JP2002103348A (en) * | 2000-09-29 | 2002-04-09 | Omron Corp | Method and apparatus for manufacturing optical part, and optical part |
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