JP2575766B2 - Manufacturing method of cushion foam - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a cushion foam used as a cushion foam body for a seat, and more particularly, to a method for foam-forming a cushion foam by being integrally joined to a seat skin. And a method for manufacturing a cushion foam to be manufactured.

2. Description of the Related Art When manufacturing this kind of cushion foam, a sheet skin in which slab material is laminated on one side is used, and the terminal side of the sheet skin is sandwiched between mating surfaces of the mold, and the sheet skin is inserted into a mold cavity. The cushion foam is placed and then foamed with a foamed resin to be filled into the cavity of the mold to integrally form the cushion foam with the slab material of the seat skin.

Problems to be Solved by the Invention At this time, if the seal of the mold is loose, and even if there is some gap that can be ventilated with a slab material on the mating surface of the mold that sandwiches the end side of the sheet skin, the cushion foam is required. Gas generated from the foamed resin to be molded may flow out of the mold through the layers of the slab material. The gas passes through and flows out until the gelling of the foamed resin has sufficiently progressed and the slab material no longer impregnates into the layer of the slab material. It becomes high hardness and causes impairment of cushioning properties. Also, even if the foamed resin does not impregnate the slab material in a large amount, a large amount of gas is discharged out of the mold, and a dense layer is generated near the interface with the slab material due to the collapse of cells. This also impairs the cushioning of the seat.

Conventionally, in order to prevent the outflow of gas, a non-breathable film is interposed on the joint surface between the slab material and the cushion foam, but a breathable sheet is formed using a breathable sheet skin. In this case, the air permeability of the cushion foam is interrupted, so that the foam becomes not only extremely humid, but also the cushion foam and the sheet skin are peeled off, causing cell roughening. It is unavoidable that the cost is high with such a thing.

Means for Solving the Problems In the method for manufacturing a cushion foam according to the present invention, the terminal side of a sheet skin backed by a slab material is inserted into an appropriate inner surface of a mold that is separated from a mating surface of a mold. A large recess is provided, and the recess is used as a reservoir for gas generated from the foamed resin, so that the slab material of the seat skin and the cushion foam are integrally formed by foaming without causing gas to flow out from the terminal side of the seat skin. .

In this cushion foam manufacturing method, gas flow exhausted from the terminal side of the seat skin does not occur at least through the interlayer of the slab material, so that the slab material of the seat skin is appropriately impregnated with the foam resin to integrate the cushion foam. It can be foam molded.

Embodiment The following is a description with reference to the accompanying drawings.

As shown in FIG. 1, this method of manufacturing a cushion foam is applied to use a sheet skin C in which a slab material S is laminated on one side and integrally bond the cushion foam with a foamed resin E such as urethane. . Also,
In this foam molding, a mold having an upper mold 10 and a lower mold 11 and having a relatively large recess 12 provided on the inner surface of the mold at a position deviating from the mating surface of each mold 10 and 11 is used. Have been done. This recess 12 partially divides the lower mold 11 and
It is provided by notching and forming 11a and firmly fixing the split surface with bolts 11b. Further, the recess 12 is provided over the entire circumference of the lower mold 11, and a recess serving as a relatively large gas reservoir may be further provided at least at a corner position.

In the molds 10 and 11, the slab material S is directed to the upper mold side, and the sheet skin C is arranged in the cavity of the lower mold 11 with the sheet skin C along the mold surface. After the mold is clamped by inserting the foamed resin into the cavity through the injection port 10a, the cushion foam can be foamed. When the terminal side of the sheet skin C is inserted into the recess 12, a fastening member such as a trim cord T is attached to the terminal of the sheet skin C in advance as shown in FIG. By locking, the seat skin C can be positioned and arranged in the cavity of the lower mold 11.

When the cushion foam is foam-molded in this way, although the gas is appropriately discharged from the vent holes 10b, the recess 12 in which the terminal side of the seat skin C is inserted acts as a foam gas reservoir, and No foaming gas flows out of the recess 12. Therefore, since there is no gas flow flowing at least to the terminal side of the sheet skin C through the interlayer of the slab material S, the foaming gas impregnating the slab material S can be kept in an appropriate amount, and a large amount of foaming gas is contained in the cushion foam. There is no formation of a dense layer due to cell collapse caused by the outflow. Further, even when a breathable sheet is formed using a breathable sheet skin such as a fabric, the slab material S can be formed with good breathability because the foamed resin impregnating the slab material S can be kept in an appropriate amount.

As shown in FIG. 3, this cushion foam can be integrally formed as a whole, including the seating surface and the bank. In this case, a trim cord T attached to the end of the seat skin C attaches to the seat frame F. C can be fixed and fixed. Further, as shown in FIG. 4, the seat surface portion and the bank portion can be formed separately. In this case, the listing wire W is provided at a sewing position between the skin terminal of the seat surface portion and the skin terminal of the bank portion. The seat can be fastened by interposing the seat skin on the cushion spring P with a C-shaped ring R or the like.

The cushioning material D of the cushion spring P can be integrally foamed as shown in FIGS. If the cushioning material D is sandwiched between the mating surfaces of the molds 10 and 11 to foam-mold the cushion foam, the foaming resin which slightly flows out together with the foaming gas is impregnated into the portion to exhibit a high hardness, so that the terminal is formed. It can be securely fixed to the seat frame F with a C-shaped ring or the like.

Effect of the Invention As described above, according to the cushion foam manufacturing method of the present invention, the foamed resin can be appropriately impregnated and integrated into the slab material of the sheet skin, so that delamination does not occur, and the method is excellent. It is possible to foam the cushion foam integrally with the seat skin by retaining the cushioning property.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an explanatory view showing a method of manufacturing a cushion foam according to the present invention, FIG. 2 is a partially enlarged sectional view of a mold applied to the manufacturing method, and FIGS. It is explanatory drawing which shows the assembly structure of the cushion foam manufactured by the method. 10, 11: mold, 12: recess, S: slab material, C: sheet skin, E:
Foam resin.

Claims (2)

(57) [Claims] 1. A relatively large recess for inserting a terminal side of a sheet skin backed by a slab material is provided on an appropriate inner surface of a mold deviating from a mating surface portion of a mold, and the recess is formed from a foamed resin. A method of manufacturing a cushion foam, wherein a slab material of a seat skin and a cushion foam are integrally foam-molded without causing gas to flow out from a terminal side of the seat skin as a gas reservoir. 2. A fastening member such as a trim cord is attached to a terminal side of the sheet skin, and the fastening member is locked in a recess so that the terminal side of the sheet skin is positioned and arranged in a mold. The method for producing a cushion foam according to claim 1.