JP2548986B2 - Molding equipment for molding products - Google Patents

Description

TECHNICAL FIELD The present invention relates to a member and an apparatus suitable for molding a molding material-coated product. The invention is suitable for producing "in-situ foaming" products, such as headrests (for vehicles, for example), backs and seat cushions, seat accessories, ottomans, which are a type of chaise longue, and the like.

[Prior Art and its Problems] For example, when manufacturing a seat cushion, a mold is set to an impermeable material (which is impermeable to the foaming material), and the periphery of the mold is held by a slip ring. . Excess material runs off the slip ring,
Vacuum suction of material into the mold draws some of the excess material inside the slip ring. Obviously, the pressure of the slip ring acting on the material regulates the amount of material drawn into the mold. When the pressure by the slip ring is increased to hold the material, more material is drawn by the vacuum action and the drawn material is sucked into the mold according to the inner contour of the mold. However, thin spots may occur. Further, even if the pressure of the slip ring is reduced, more material may be drawn into the forming mold according to the inner surface contour of the forming mold, and in this case, wrinkles will occur.

Another problem of the above-mentioned conventional method is that the operation of positioning each material in the mold depends on the operator. For each material, the worker uses his judgment to clamp the mold and stick to the material forming the inside of the final product, for example, the thin spots on the material inside the mold before the polyurethane foam material is injected into the mold. In order to prevent wrinkles and wrinkles, it is necessary to reliably suck a sufficient material into the mold with a sufficient stretching force. In this case, the worker must repeat this operation for each operation to produce a final product that is slightly different from the next final product.

Furthermore, it is necessary to remove excess material after forming seats and seat cushions for vehicles, for example. In addition, it is then necessary to sew or fix the mounting skirt on the peripheral edge of the seat cushion. Often the material used for this is a stretchable material (eg Lycra-lycra) that is sewn tightly so that it can be stretched, but such materials are costly.

That is, it is an object of the present invention to provide improved products.

Another object of the invention is to reduce the molding time of the product.

Yet another object of the present invention is to reduce the manufacturing cost of the above products.

Yet another object of the present invention is to manufacture the above products using low cost materials.

Yet another object of the present invention is to provide a device having fewer parts than the improved member and alternative device.

[Means for Solving the Problems] Those skilled in the art should understand still another object of the present invention from the detailed description given below regarding the embodiments of the present invention.

According to one aspect of the invention, in a mold for forming a product using a bag or sack of material, (a) at least two parts, namely (i) a bottom part and (i)
i) Separated tongue that sits on the bottom, has a design, and is movable (rotatable) from a seated position on the bottom to a position lifted from the bottom (for example, it rotates at one end to the position lifted from the bottom). A lower mold (which can be given a design), and (b) a sidewall structure that is movable relative to the bottom (eg, a sidewall structure consisting of a plurality of interrupted walls that, when joined, form a sidewall structure). A mold comprising a body is provided.

A notch may be provided in the lower portion of the bottom edge so as to fully engage the lower end of the sidewall structure. The tongue may be provided with an opening for connection to a vacuum source. If calibrated in this way, a backrest or other molded body can be manufactured.

It consists of segments that can be operated independently.
If mechanical means such as plugs are used to mechanically position the material relative to the design surface of the lower part of the mold, then the segmented parts of the plugs can be operated individually (independently) Good. Preferably, each segment is used continuously. Normally, first use the segment in the center of the plug first. Each segment is used radially outward from the center towards the edge. When bubbles are used, for example, the material is blown up and the material is mechanically processed from the outside (periphery) of the mold toward the center.

DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION Hereinafter, preferred embodiments of the present invention will be described with reference to the attached FIGS.

First, referring to FIG. 1, the illustrated automobile seat
20 is a seat cushion 22, a backrest 24 with armrests 26, 28
And headrest 30. The backrest 24 is rotatable on the seat 20 side with respect to the seat cushion 22 by a mechanism 32. The seat cushion 22 is attached to the lower supports 32 and 34.

FIG. 2 shows the seat cushion 38 before it is assembled to the seat 20.
FIG. The seat cushion comprises a contour line 40, which is a fabric material 42 that is impermeable to the foaming material [ie, the material 44 is formed by injection molding a foaming polyurethane foam material 44 into a mold (not shown). It consists of a fixed material 42]. Mold from seat cushion 38
After removing the, the material 42 is then secured to the seat 20,
The side surface of the seat cushion 38 is formed.

Referring now to FIGS. 3 and 4, shown is an improved mold for molding products such as a backrest shown at 200 in FIG. 3 using a material "bag" or "sack". Is. The mold 202 comprises a lower mold 204 whose upper surface design is the outer surface of the bag or sack. Lower mold 20
4 can be separated into two parts, a bottom 208 and a rotatable tongue (ie a rotatable tongue-shaped structure, and so on) 210, which tongues to the bottom 208 of the support 214. The part 212 is rotatable. The tongue 210 can be pivoted from a position where it engages the bottom 208 (FIGS. 3-4) to lift an end 216 from the bottom 208 and into which the sack 200 is inserted. Further, the molding die 202 is provided with a side wall structure 220 that can move relative to the lower die 204. The lower mold 204 is provided with a notch 222 that allows the lower end of the side wall structure 220 to be sufficiently engaged.
Also, the tongue 210 includes pipes and conduits internally below the surface 206, which are attached to a gas pump that supplies gas to the surface 206 through the openings 226 and air from the interior of the molding cavity through the openings 226. , Connected to the vacuum pump for suction of the conduit shown in FIG. The opening 206 is the collection conduit 2
28, and this conduit 228 connects to a larger conduit.

Explaining the "bag" or "sack" 200, it is the "A side" 242 of the backrest and the "B side" of the opposite side.
Made of material 240 made of surface "244" (see FIG. 4).
And a material sheet 240 consisting of
It constitutes a "bag" or "sack" with sides 246, 248 and back 250. "Stopping means" 252 (see FIG. 4) formed by welting stitched between the peripheral edge of the material 240 and the parts constituting the side and back parts 246, 248 and 250.
To provide. In this case, the portions 246, 248 and 250 are composed of one sheet of material, each being a portion of a larger sheet 250 '. After making a "bag" or "sack", with the inside out, as shown in Figs. 3 and 5,
Pivot the tongue 210 with respect to the support 214, lift it and insert the "bag" into it. Then tongue 21
Return 0 to the position shown in FIG.
After tightening 0 between bottom 208 and tongue 210, side wall 220
4 to the position shown in FIG. 4 and then “blowing up” the material 240 with air introduced from the air pump through the opening 226, making it impossible to pass between the side wall 220 and the periphery of the tongue 210. After sucking the "stopping means" 252 at the position shown, activate the vacuum pump (not shown) to
Air is drawn between 210 and the material 240 to bring the material into close contact with the tongue face 206 and match the design of the tongue on the face 206. In this case, a positioning machine with individually steerable segments may be used. Next, the side wall structure is lowered, the sheet 240 is tightened, and then the uppermost part of the mold is lowered onto the side wall, and the expandable thermoplastic material is injected from the injection nozzle 260 to obtain a finished product.

FIG. 4 shows a suitable aligning / locking device for aligning / contacting members.

After the molding operation is finished, the uppermost part 203 is lifted, the side wall is lifted, and the "sack" having the foamed thermoplastic material conforming to the shape of the molding cavity is formed from the tongue rotatable at the end 212 with respect to the support 214. Remove. The finished product is in the state shown in Fig. 5 (inside out), which is "B side" 244
On top 270 and 272 have foamed thermoplastic material.

Referring to FIG. 6, the “sack” is “in the state in which the right side is outside” and is ready to be attached and used.

Many variations are possible in embodiments according to the present invention (eg, the stopping means used may comprise different seams, for example deck seams, French seams or seams or welchings of at least about 50 different seams). . Therefore, the description of the embodiments is for illustrative purposes only.

[Brief description of drawings]

FIG. 1 is a perspective view of an automobile seat constructed according to an embodiment of the present invention, and FIG. 2 is a sectional view showing a part of a seat cushion of an automobile seat constructed according to an embodiment of the present invention. FIG. 3 is a view showing another forming apparatus according to another embodiment of the present invention, and is an exploded perspective view showing a state of forming an automobile seat using the same, and FIG. FIG. 6 is a transverse cross-sectional view showing a usage state of the apparatus of FIG. 3, FIG. 5 is a diagram illustrating a molded backrest body manufactured by using the apparatus of FIGS. 3 to 4, and FIG. The figure is a diagram showing a state in which the product of FIG. 5 is reversed and the outer surface of the sack is exposed. 20 is a seat, 24 is a seat back, 30 is a headrest, 38 is a seat cushion, 44 is a polyurethane foam, 202 is a mold, 252 is a stopping means, 210 is a tongue (that is, a tongue-shaped structure), and 260 is a nozzle. is there.

 ─────────────────────────────────────────────────── ─── Continuation of front page (56) Reference JP 54-159466 (JP, A) JP 56-111668 (JP, A) JP 61-280908 (JP, A) Actual 60- 145020 (JP, U) Actually opened Sho 64-36117 (JP, U) Actually opened 62-189113 (JP, U)

Claims (6)

(57) [Claims] 1. A molding die for a product, comprising a material bag having a front seat surface and a back seat surface, one end and left and right sides of which are closed and the other end is open, comprising: (a) A lower mold comprising at least two separable components: (i) a bottom; (ii) a rotatable rotatable tongue-shaped structure, wherein the tongue-shaped structure is now Has one end pivotally attached to the bottom portion and is rotatable to receive the material bag, the design correspondingly forming a design of the front sheet surface of the material bag, And the tongue-shaped forming structure receives or separates the material bag in the raised position, and is seated on the bottom through the back seat surface of the material bag in the lowered forming position; (b) the peripheral edge of the lower mold. It is provided so that it can move back and forth with respect to the A side wall structure for adhering a foam material layer to a material bag while maintaining the design; 2. The molding die according to claim 1, wherein a peripheral portion of the lower die is notched so that the material bag can be fitted between the sidewall and the lower end of the sidewall structure. 3. The molding die according to claim 1, wherein the rotatable tongue-shaped molding structure has a plurality of through holes capable of communicating with a vacuum source. 4. A molding device for molding a foam material at a predetermined position of a cover material forming a bag-like structure for forming a backrest body, wherein the bag-like structure has a front seat surface and a back seat surface. And one end and left and right sides of each other are closed and the other end is opened, and the molding device corresponds to the shape inside the bag-shaped structure through the opening of the bag-shaped structure. And a tongue-shaped forming structure having a shape and a dimension that spreads, and the tongue-shaped forming structure is provided on the outer surface of the front seat surface of the bag-shaped structure when the bag-shaped structure is inserted inside out. A support body having a corresponding predetermined molding surface and supporting the tongue-shaped molding structure, wherein (i) the tongue-shaped molding structure is cantilevered to support the bag-shaped structure inside out. To the tongue-shaped structure, or tongue-shaped structure The tongue-shaped structure so that the bag-shaped structure is detached from the bag-shaped structure and (ii) the tongue-shaped structure is supported and seated via the back seat surface of the bag-shaped structure. And a side wall structure provided in relation to the tongue-shaped molding structure, and (i) a bag-shaped structure spaced apart from the tongue-shaped molding structure. A non-molding position where it is attached to and detached from the body,
(Ii) a forming position that extends along the peripheral edge of the front sheet surface of the mounted bag-shaped structure, and a plurality of through holes that are opened on the forming surface of the tongue-shaped structure. To form a vacuum pressure between the front sheet of the bag-shaped structure and the molding surface of the tongue-shaped forming structure, whereby the outer surface of the surface front sheet is made to contact the molding surface of the tongue-shaped forming structure. What is molded according to the shape, and the molding lid, which moves relative to each other in relation to the side wall structure, and closely adheres to the side wall of the side wall structure at the time of molding, and these side wall structure and the front face sheet. And a foamed material that forms a sealed space that adheres to the front sheet by foaming the foamed material. 5. The tongue-shaped structure is pivotally attached to a support through one end thereof, and the tongue-shaped structure is in a raised position when the bag-shaped structure is attached or detached. The molding apparatus according to claim 4, wherein: 6. When the tongue-shaped structure and the support are in a molding position with the bag-shaped structure crowned with the tongue-shaped structure, a part of the peripheral edge of the bag-shaped structure extends from between them. The molding apparatus according to claim 4, wherein the molding apparatus is formed so as to be in a released and free state.