JP2023081777A - Method for manufacturing foamed molded article, and mold - Google Patents

Abstract

To facilitate manufacturing of a foamed molded article in which an insert article is insert-molded.SOLUTION: A mold 31 having at least one contact portion 33 and a protrusion 34 formed at a predetermined position of an upper mold 32 is used, and an insert article 13 having an end face 13a that touches a contact face 33a of the contact portion 33 of the upper mold 32, and having a fitting portion 20 that fits into the protrusion 34, is used. A back face of the insert article 13 is allowed to face the upper mold 32 in a state in which the mold 31 is opened and the end face 13a of the insert article 13 is butted against the contact face 33a of the contact portion 33 of the upper mold 32, to press the back face of the insert article 13 against the upper mold 32. Thereby, the fitting portion 20 of the insert article 13 is fit into the protrusion 34 of the upper mold 32 to set the insert article 13 to a predetermined set position of the upper mold 32. Thereafter, a foamable raw material 38 is injected into a lower mold 35, the mold 31 is closed, and the foamable raw material 38 is foamed, to mold a pad material 12. Thus, the insert article 13 is insert-molded in the pad material 12.SELECTED DRAWING: Figure 1

Description

TECHNICAL FIELD The present invention relates to a foam-molded product manufacturing method and a mold for manufacturing a foam-molded product in which an insert is insert-molded in a pad material.

As this type of foam-molded product, for example, a seat back for a backrest portion of a seat mounted in an automobile or the like, a seat cushion for a seat portion, and the like are known. In order to support the occupant's body well to reduce fatigue and to reduce the weight of the foam-molded product, when forming the pad material by foaming the foamable raw material in the mold, In some cases, a foam molded product is manufactured by embedding an insert product molded into a predetermined shape with foam beads or the like and insert molding the insert product into a pad material. As a method for producing such a foamed molded article, for example, the production method described in Patent Document 1 (Japanese Patent Application Laid-Open No. 9-70836) is known.

In the manufacturing method described in Patent Document 1, a shock absorbing pad as an insert is placed in a mold having a structure in which a middle mold (core mold) is inserted between a lower mold and an upper mold. In a manufacturing method for manufacturing an automotive seat back in which the shock absorbing pad is insert-molded by injecting a foaming raw material into a mold and foaming it, the middle mold is provided with a projection on the side thereof, A concave portion into which the projection can be press-fitted is formed on the surface of the impact-absorbing pad, and when an operator places the impact-absorbing pad in the molding die, the medium-sized projection is press-fitted into the recess of the impact-absorbing pad. , the shock absorbing pad is detachably attached to the medium size. At this time, by press-fitting the projections of the medium size into the concave portions of the shock absorption pad, the shock absorption pad is mounted in the correct position on the medium size with the correct posture, and the shock absorption pad is prevented from slipping when the mold is subsequently closed. It has become.

JP-A-9-70836

However, in the manufacturing method of Patent Document 1, depending on the size of the shock absorbing pad which is an insert product and the positional relationship between the worker and the shock absorbing pad, the worker holds the shock absorbing pad and visually detects a medium-sized protrusion. It may be difficult to confirm, and it may be difficult to press-fit the medium-sized protrusion into the recess of the shock absorbing pad.

Therefore, the problem to be solved by the present invention is to provide a method for manufacturing a foam-molded article and a mold that facilitates the operator's work of setting an insert article in an upper mold.

In order to solve the above problems, the invention according to claim 1 provides a method for manufacturing a foamed molded product in which an insert is insert-molded in a pad material using a mold having at least an upper mold and a lower mold, The mold has at least one abutment portion and a projection for positioning the set position of the insert product at a predetermined position of the upper mold, and the abutment portion faces the projection. An insert having an abutment surface is used, and the insert part has an end face abutting against the abutment surface of the abutment portion of the upper die and a fitting portion that fits into the projection. a step of abutting the end surface of the insert against the abutting surface of the abutting portion of the upper mold while the mold is open; a step of facing the back surface of the insert product against the upper mold while abutting against the contact surface of the part; a step of fitting the insert into the protrusion of the upper mold to set the insert at a predetermined setting position of the upper mold; injecting a foamable raw material into the lower mold and closing the mold to foam the pad material; and insert-molding the insert into the pad material.

In this manufacturing method, when the operator sets the insert in the upper mold, the end face of the insert is brought into contact with the contact surface of the contact portion of the upper mold, thereby facilitating rough positioning of the insert with respect to the upper mold. can be defined in Then, with the end face of the insert in contact with the contact surface of the contact part of the upper die, the back surface of the insert is opposed to the upper die, so that the fitting part of the insert is directly (automatically) placed on the upper die. can be located at a position corresponding to the protrusion of the As a result, the operator can easily fit the fitting portion of the insert into the protrusion of the upper die by pressing the back surface of the insert against the upper die without visually checking the protrusion of the upper die. An operator can set the insert product to the predetermined set position of the upper mold with a simple operation.

In this case, the fitting portion of the insert that fits into the protrusion of the upper die may be a recess having a shape matching the shape of the protrusion of the upper die. It may be a through hole. In the case of a through hole, it is possible to visually confirm that the protrusion of the upper die is passed through and that the insert product is set at a predetermined position of the upper die.

Furthermore, as in claim 3, before setting the insert product on the upper mold, after setting the back surface auxiliary material on the upper mold, the upper mold is arranged so that the insert product overlaps at least a part of the back surface auxiliary material. You can set it to . In this way, the back support material covering the back surface of the foam molded product and the insert can be integrated with the pad material.

Also, as in claim 4, the size of the fitting portion of the insert may be slightly smaller than the size of the projection of the upper die. In this way, the insert is set in the upper mold while the fitting part of the insert and the protrusion of the upper mold are in strong contact, so that the insert is less likely to be displaced when the mold is closed. It is possible to make it difficult to remove from the upper mold.

Furthermore, as in claim 5, the length from the portion of the fitting portion of the insert closest to the end face of the insert to the end face should It is preferable that the contact surface is formed slightly smaller than the length from the portion near the contact surface to the contact surface. With this arrangement, the insert is set in the upper mold while being sandwiched between the protrusion of the upper mold and the contact surface of the contact portion, so that when the mold is closed, foaming is prevented. Even when the raw material is foaming and flowing, it is possible to make it difficult for the insert product to shift its position or to come off from the upper mold.

In addition, as in claim 6, it is preferable that at least a part of the contact portion of the upper mold is positioned above the protrusion when the mold is opened. This makes it easier for the operator to visually confirm the abutting portion of the upper die while holding the insert.

The mold used in the invention of the "method for manufacturing a foam molded product" according to claim 1 has at least an upper mold and a lower mold as in claim 7, and the upper mold has an insert part. At least one abutment portion with which an end surface abuts, and a protrusion that fits into the fitting portion when the back surface of the insert is pressed against the upper mold while the end surface abuts against the abutment portion. A formed mold may be used.

FIG. 1 is a perspective view of a foam molded article according to one embodiment of the present invention. FIG. 2 is a perspective view of an insert. FIG. 3 is a cross-sectional view explaining the process of opening the mold and setting the insert product in the upper mold. FIG. 4 is a cross-sectional view showing a state in which the mold is opened and the insert is set in the upper mold. FIG. 5 is a cross-sectional view showing a state in which the foaming raw material is injected into the lower mold and the mold is closed. FIG. 6 is a plan view of the upper die. FIG. 7 is a plan view showing a state in which the back surface support material is set on the upper mold. FIG. 8 is a plan view showing a state in which an insert product is set in the upper mold.

An embodiment in which the mode for carrying out the present invention is applied to a method of manufacturing a cushion material for a vehicle seat back (backrest) will be described below.

First, the structure of the cushion material 11 of the vehicle seatback manufactured by the manufacturing method of the present embodiment will be described with reference to FIG.

A cushion material 11 of a vehicle seatback is a foam-molded product in which an insert part 13 is insert-molded into a pad material 12 which is a foam cushion material. The pad material 12 is made by injecting a liquid foamable raw material 38 (for example, a foamable polyurethane raw material obtained by mixing a foaming agent such as water into a mixed raw material of a polyol-based resin raw material and an isocyanate-based resin raw material) into a molding die 31 to be described later. It is foam-molded. Left and right pad side portions 14 and 15 for stabilizing the seated posture of the occupant are integrally formed on the left and right side portions of the pad material 12 so as to stand on the front side.

On the other hand, the insert part 13 is formed of foamed resin such as foamed beads, and as shown in FIGS. are integrally formed, the center portion 16 is embedded in the pad main portion 12a of the pad material 12, and the left and right side portions 17 and 18 are embedded in the left and right pad side portions 14 and 15 of the pad material 12, respectively, by insert molding.

As shown in FIGS. 3 to 6, the insert part 13 has an end surface 13a (upper end surface in this embodiment) that contacts the contact surface 33a of the contact portion 33 of the upper die 32 described later, and a projection of the upper die 32 described later. and a fitting portion 20 that fits into the portion 34 . The fitting portion 20 may be a recess having a shape matching the shape of the projection 34 of the upper mold 32, but in this embodiment, the fitting portion 20 has a cross-sectional shape of the projection 34 of the upper mold 32 It is formed as a through-hole (circular through-hole in this embodiment) having a cross-sectional shape (circular cross-section in this embodiment) that matches the size (diameter) of the fitting portion 20 is slightly smaller than the size (diameter) of the protrusion 34 of the upper die 32 . As a result, even when the inner peripheral surface of the fitting portion 20 comes into contact with the outer peripheral surface of the projecting portion 34 to close the molding die 31 or when the foamable raw material 38 is foaming and flowing, the insert 13 is kept away from the upper mold 32. It is designed not to come off.

As shown in FIG. 8, the length H from the portion closest to the end face 13a of the insert 13 in the fitting portion 20 of the insert 13 to the end face 13a is It is formed slightly smaller than the length h (see FIG. 6) from a portion of the contact portion 33 near the contact surface 33a to the contact surface 33a. As a result, the insert 13 is sandwiched between the projecting portion 34 of the upper mold 32 and the abutting portion 33, and the insert 13 is held even when the molding die 31 is closed or when the foamable raw material 38 is foaming and flowing. is prevented from being displaced or detached from the upper die 32.例文帳に追加

On the other hand, on the back surface of the pad material 12, a back support material 21 (see FIGS. 7 and 8) covering the back surface of the pad material 12 is insert-molded together with the insert part 13 to integrate these three parts. The back support member 21 is formed by sewing a cloth-like member such as a non-woven fabric cut into a predetermined shape, and corresponds to the contact portion 33 and the protrusion 34 of the upper mold 32 of the back support member 21, which will be described later. Through holes 22 and 23 through which the contact portion 33 and the protrusion 34 can pass are formed at the positions. This backside supplementary material 21 reinforces the pad material 12 and prevents the pad material 12 and the insert 13 from coming into direct contact with the frame (not shown) to which the cushion material 11 is attached, thereby preventing the generation of abnormal noise. Fulfill.

Next, the configuration of the mold 31 for molding the cushion material 11 will be described with reference to FIGS. 3 to 8. FIG.
The molding die 31 is arranged to mold the cushion material 11 with the front side (the side facing the back of the person sitting) facing downward, and comprises at least an upper die 32 and a lower die 35 . The upper die 32 is attached to the lower die 35 via a hinge shaft 36 so as to be openable and rotatable. At a predetermined position of the upper die 32, at least one abutment portion 33 and a protrusion 34 are formed for positioning the set position of the insert 13. As shown in FIG. The contact portion 33 and the protrusion 34 may be formed integrally with the upper die 32, or may be formed by attaching separate parts.

In this embodiment, as shown in FIG. 6, two abutting portions 33 and two protruding portions 34 are formed at symmetrical positions, and the end face 13a of the insert 13 abuts against the abutting portion 33. By pressing the back surface of the insert 13 against the upper mold 32, the fitting portion 20 of the insert 13 is (automatically) fitted into the projection 34 as it is. As shown in FIGS. 3 and 4, the positional relationship between the contact portion 33 of the upper mold 32 and the projection 34 is such that at least a portion of the contact portion 33 of the upper mold 32 is positioned in the state where the mold 31 is opened. is positioned above the projection 34 .

Next, a method of manufacturing the cushioning material 11 using the molding die 31 will be described.
First, as shown in FIG. 3, the worker sets the back surface support member 21 on the inner surface of the upper mold 32 while the mold 31 is open. At this time, as shown in FIG. 7 , holes 22 and 23 are formed in the rear surface support member 21 so as to avoid the contact portion 33 and the protrusion 34 of the upper die 32 .

Thereafter, as shown in FIG. 3, the operator holds the insert 13 and brings the upper end surface 13a of the insert 13 into contact with the contact surface 33a of the contact portion 33 of the upper die 32. Then, as shown in FIG. Thereby, the rough position of the insert 13 with respect to the upper die 32 is determined. In this embodiment, when the molding die 31 is opened, at least a part of the contact portion 33 of the upper mold 32 is positioned above the projecting portion 34. , the contact portion 33 of the upper die 32 can be easily confirmed visually.

Then, the back surface of the insert 13 is opposed to the upper die 32 while the upper end surface 13 a of the insert 13 is in contact with the contact surface 33 a of the contact portion 33 of the upper die 32 . As a result, the fitting portion 20 of the insert 13 is (automatically) positioned at a position corresponding to the projection 34 of the upper die 32, and the insert 13 is attached to at least a part of the back surface support member 21. become overlapped. In this state, as shown in FIG. 4, by pressing the back surface of the insert 13 against the upper mold 32, the fitting portion 20 of the insert 13 is fitted into the protrusion 34 of the upper mold 32, and the insert 13 is is set at a predetermined set position of the upper mold 32 . As a result, the fitting portion 20 of the insert 13 can be easily fitted to the protrusion 34 of the upper die 32 by pressing the back surface of the insert 13 against the upper die 32 without the worker visually checking the protrusion 34 of the upper die 32 . can be fitted in.

In this embodiment, since the fitting portion 20 of the insert 13 is a through hole, the insert 13 is set in the upper mold 32 by fitting the fitting portion 20 of the insert 13 into the projection 34 of the upper mold 32. You can see what you have done.

Furthermore, in this embodiment, the size of the fitting portion 20 of the insert 13 is formed slightly smaller than the size of the protrusion 34 of the upper die 32, so that the fitting portion 20 of the insert 13 can be The insert product 13 is set in the upper mold 32 in a state where the peripheral surface and the outer peripheral surface of the protrusion 34 of the upper mold 32 strongly abut each other. This makes it difficult for the insert 13 to come off from the upper mold 32 when the mold 31 is closed.

Moreover, in this embodiment, the length H from the portion of the fitting portion 20 of the insert 13 closest to the end face 13a of the insert 13 to the end face 13a is the longest of the projections 34 of the upper die 32. Since the contact portion 33 is formed slightly smaller than the length h from the portion near the contact surface 33a of the contact portion 33 to the contact surface 33a, the insert 13 is formed between the protrusion 34 of the upper die 32 and the contact portion 33. The insert 13 is set in the upper mold 32 while being sandwiched between the contact surface 33a. This makes it difficult for the insert 13 to come off from the upper mold 32 when the mold 31 is closed.

After setting the insert 13, a foamable raw material 38 such as a foamable polyurethane raw material is injected into the lower mold 35, and then, as shown in FIG. A cushion material 11 is formed by filling a foamed raw material 38 into a cavity in a mold 31 to form a pad material 12, and integrating an insert part 13 and a back support material 21 on the back side of the pad material 12 by insert molding. to manufacture.

In this embodiment, the upper end surface 13a of the insert 13 is abutted against the contact surface 33a of the contact portion 33 of the upper die 32. Therefore, even if the insert 13 is large, the operator can press the insert 13. There is an advantage that the upper end face 13a of the insert part 13 can be easily brought into contact with the contact face 33a of the contact portion 33 of the upper mold 32. It may be made to abut against a contact surface of a contact portion formed at a predetermined position 32 .

Further, the present invention may be applied to a mold whose upper mold includes a core mold, and in this case, the core mold may be configured to have at least one contact portion and a projection. The number of contact portions and protrusions is not limited to two, and may be one or three or more.

In addition, in this embodiment, the insert 13 is embedded in the pad material 12 and the back surface of the insert 13 is covered with the back surface support material 21. may be embedded in

In addition, the scope of application of the present invention is not limited to the method of manufacturing a cushioning material for a vehicle seatback, but a foaming method in which an insert is insert-molded into a pad material using a mold having at least an upper mold and a lower mold. It can be widely applied to methods for manufacturing molded articles.

DESCRIPTION OF SYMBOLS 11...Cushion material (foam molding product) of seat back for vehicles, 12...Pad material, 12a...Pad main part, 13...Insert part, 13a...End face, 14, 15...Pad side part, 16...Center part, 17, Reference numeral 18: Side portion 20: Fitting portion 21: Back side auxiliary material 22, 23: Hole 31: Mold 32: Upper mold 33: Contact portion 33a: Contact surface 34: Protrusion 35... lower mold, 38... foaming raw material

Claims (7)

In a method for manufacturing a foamed molded product in which an insert is insert-molded into a pad material using a mold having at least an upper mold and a lower mold,
The mold has at least one abutment portion and a projection for positioning the set position of the insert product at a predetermined position of the upper mold, and the abutment portion faces the projection. Use one with a contact surface,
The insert part has an end face that contacts the contact surface of the contact part of the upper mold and a fitting part that fits into the protrusion,
a step of abutting the end surface of the insert against the contact surface of the contact portion of the upper mold while the mold is open;
a step of causing the back surface of the insert to face the upper mold while the end surface of the insert is in contact with the contact surface of the contact portion of the upper mold;
a step of pressing the back surface of the insert product against the upper mold to fit the fitting portion of the insert product into the projecting portion of the upper mold to set the insert product at a predetermined set position of the upper mold; ,
a step of injecting a foamable raw material into the lower mold, closing the mold, foam-molding the pad material, and insert-molding the insert into the pad material. Method. 2. The method of manufacturing a foam molded product according to claim 1, wherein the fitting portion of the insert product is a through hole. The insert is set on the upper mold so as to overlap at least a part of the back surface supplement after setting the back surface supplement on the upper mold before setting the insert product on the upper mold. The method for producing a foam molded article according to claim 1 or 2. 4. The molded foam product according to any one of claims 1 to 3, wherein the size of said fitting portion of said insert is slightly smaller than the size of said protrusion of said upper mold. manufacturing method. The length from the portion closest to the end surface of the insert product in the fitting portion of the insert product to the end surface is the contact surface of the contact portion closest to the protrusion of the upper die. 5. The method for manufacturing a foamed molded product according to claim 1, wherein the length of the contact surface is slightly smaller than the length from the portion near the contact surface. 6. The mold according to any one of claims 1 to 5, wherein at least a portion of said contact portion of said upper mold is formed to be positioned above said projecting portion when said molding die is opened. 3. The method for producing the foam molded article according to 1. A mold for manufacturing a foam molded product in which an insert having at least one end surface and a fitting portion is insert-molded into a pad material,
having at least an upper mold and a lower mold,
The upper mold includes at least one abutment portion that abuts against the end face of the insert, and when the back surface of the insert is pressed against the upper mold while the end face abuts against the abutment, the A mold, characterized in that a protrusion that fits into the fitting portion is formed.

Images