JP2583278B2 - Foam molding method - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a foam molding method suitable for use in molding a seat pad of a vehicle seat, and relates to a foam product having characteristics (specified in JASO-B408). And foaming materials having different physical properties due to the combination of hot-cured foam and cold-cured foam).

Here, the seat pad includes both a seat cushion and a back pad.

(Prior Art) Conventionally known methods of manufacturing a seat pad for an automobile include, for example, a desired portion of a foam preliminarily formed using a single type of foam material, and another foam having different characteristics from the foamed material. In addition to the method of sticking after the fact, as shown in FIG.
In the lower mold 1, after the second foaming liquid 3 is penetrated below the first foaming liquid 2 in the middle of foaming, or beforehand distributed in the lower mold 1 as shown in FIG. After injecting the foaming undiluted solution 5 onto the foam 4 provided, there is a method of sequentially closing, heating and cooling the upper and lower molds in a horizontal plane as shown by phantom lines in the figure. According to this, an automobile seat pad made of two kinds of foam materials having different characteristics can be manufactured.

(Problems to be Solved by the Invention) By the way, among such conventional techniques, in the case of pasting another foam to a preformed foam, in addition to the molding, the foam for pasting is used. In addition to the problem that the number of man-hours is required and the cost of the seat pad is increased, there is a problem that the appearance is likely to be deteriorated due to the displacement of the adhesive foam, and FIG. In the prior art shown, the two types of foaming undiluted solutions 2, 3 and, consequently, the mixing of the two types of foaming materials cannot be effectively prevented, and the desired cushioning properties of the seat pad can be realized. It is extremely difficult and has a problem of poor reproducibility of quality. Further, in the prior art shown in FIG. 5, the man-hour and cost due to setting the foam 4 on the lower mold 1 are reduced. Can avoid the increase In addition to this, there is a problem that the impregnation layer of the foaming solution 5 with the foaming stock solution 5 impairs the cushioning properties of the seat pad.

The present invention provides a foam molding method which solves all of these problems of the prior art.

(Means for Solving the Problems) In the foam molding method of the present invention, molding is performed by a foam mold including a front mold for molding a front side portion of a foamed product and a back mold for molding a back side portion thereof. When performing, on the molding surface of each of the front mold and the back mold that are opened almost horizontally,
Inject or spray each of the different foaming stock solutions to foam them, and then 30 to 100% of the rise time of the lately supplied foaming stock solution, preferably 50 to 100%
At the timing of%, the front mold and the back mold are closed in a posture facing upward from the horizontal plane, for example, in a vertical posture.

Here, the rise time means the time from the end of the injection or spraying operation of the foaming undiluted solution to the completion of the foaming of the foaming undiluted solution finally injected or sprayed.

In this molding method, the cure of the foam is
After the mold is closed as described above, it can be carried out in the same manner as in the prior art. In particular, in the case of a so-called cold cure type polyurethane foam, it can be carried out at room temperature.

(Function) In this foam molding method, different types of foaming undiluted solutions are injected or sprayed on the molding surfaces of the front mold and the back mold, respectively, and then both molds are closed to form a ready-made mold in the mold. It is possible to manufacture foam products made of two types of foam materials with different characteristics extremely easily and at low cost without having to set foams or stick foams after molding. In addition, the appearance of the product can be effectively improved.

Also, here, by closing the mold at a timing of 30 to 100% of the rise time of the foaming stock solution supplied late,
Of course, the foaming undiluted solution can sufficiently prevent leakage at the time of closing the mold, as well as effectively preventing two types of foaming undiluted solutions from being mixed, and one of the undiluted solutions from diffusing into the other undiluted solution.
A foam product having the expected cushioning properties can always and reliably be manufactured.

In addition, in this method, the closing of the front mold and the back mold is performed in a posture in which the molds face upward from the horizontal plane, so that compared to the conventional technique of closing the molds in the horizontal plane, the undiluted foaming solution is used. In addition to smoothing the discharge of gas generated from the mold, the molding surface of the foamed product can be made extremely smooth, and the generation of burrs from the mating surface of both molds can be effectively prevented.

Embodiment An embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 is a view exemplifying a foaming mold used for carrying out the present invention, which molds an automobile seat pad.

Here, a pivot provided to extend in the center of the base 11
The front mold 13 for molding the front portion of the seat pad and one end of the rear mold 14 for molding the back surface of the seat pad are interconnected via a bracket (not shown), and the joint is formed by the bracket 12. The lower end of the portal frame 15 positioned straddling is pivotally supported at both ends of the pivot 12, respectively, and
A support bar 16 for adjusting the tilt angle of the portal frame 15 with respect to the base 11 is engaged with the portal frame 15.

Further, in the drawing, reference numeral 17a denotes a gas venting gate formed at the free end of the back mold 14 and communicating with the molding surface.The gas venting gate 17a is a lid member pivotally supported by the pivot 18 of the portal frame 15. With 17b, it can be closed as required.

In this example, the supporting rod 16 for adjusting the tilt angle of the portal frame 15 can be changed to a ratchet mechanism or other appropriate supporting means that can be hooked and unlocked on the lower end of the portal frame 15, and the gas release gate can be used. 17a may be formed at the free end of the front mold 13.

When forming a seat pad for an automobile using such a foaming mold, the front mold 13 and the rear mold 14 are opened almost horizontally as shown in the drawing, and the molds 13 and 1 are respectively opened.
Inject or spray each of the foaming stock solutions with different characteristics on each molding surface of 4 to foam the foam, and 30 to 100% of the rise time of the lately supplied foaming stock solution, preferably 50%
When the timing reaches about 100%, the front mold 13 and the rear mold 14 are closed in a posture facing upward from the horizontal plane.
Here, the attitude of the mold after closing the mold with respect to the horizontal plane is as follows:
In relation to the shapes of the molding surfaces of the front mold 13 and the rear mold 14 and the like, the posture in which each foaming liquid easily flows can be selected. For example, as shown in FIG. The attitude may be perpendicular to the horizontal plane, or as shown in FIG. 2B, the attitude may be at an angle θ to the horizontal plane.

As shown in the figure, the upward position of the molding die is maintained by fitting the lid member 17b to the gas release gate 17a. If the closing timing of the member 17b is to be different, the mold 1
It is preferable to provide another restraining member for hanging at least one of the members 3 and 14 and maintaining the same at an angle equal to the upright angle of the portal frame 15 with respect to the base 11.

After the mold closing is completed in this way, for example, the mold is passed through a heating furnace (not shown) to cause a reaction of the foamed undiluted solution, followed by cooling and opening of the mold. Are sequentially performed, and finally, the foamed sheet pad is removed from the mold.

According to this, on the molding surfaces of the respective molds 13 and 14,
By injecting or spraying different types of foaming stock solution,
Seat pads made of two types of foam materials with different characteristics and having the desired shape and dimensions, as well as the desired cushioning properties, can be bonded together with foams, and existing foams can be set in a mold. This makes it possible to significantly reduce the number of man-hours for manufacturing the seat pad and the cost of the seat pad as compared with the prior art, and to change the relative position of the two types of foams. This can completely prevent the appearance of the seat pad from deteriorating.

Also, here, the molds 13 and 14 are closed at timings of 30 to 100% of the rise time of the lately supplied foaming stock solution among the foaming stock solutions injected or sprayed into the molds 13 and 14, respectively. , Has the expected cushioning performance by almost certainly preventing leakage of the foaming stock solution at the time of closing the mold, mixing of both foaming stock solutions, and diffusion of one foaming stock solution to the other foaming stock solution. The seat pad can be manufactured repeatedly. Also here
When the molds 13 and 14 are closed at a timing close to 100% of the rise time of the foaming stock solution, the boundary between the foamed materials can be controlled as expected.

Incidentally, such a control of the boundary surface, after supplying the foaming undiluted solution to one of the molds, for example, laying a non-impregnated film, a net, etc. on the foaming undiluted solution, and then the mold,
By closing the mold with the other mold to which the foaming undiluted solution is supplied, it is possible to further facilitate the mold.

In addition, in this method, the mold closing posture of the front mold 13 and the rear mold 14 is set to a required posture facing upward from the horizontal plane, so that compared to the prior art in which the mold is closed in a horizontal posture, the undiluted foaming solution is used. Of the gas generated from the mold and the flow of the foaming liquid in the mold can be smoothed, and the molding surface of the seat pad can be made extremely smooth. Can be effectively prevented.

Further, by curing the foam while maintaining the two dies 13 and 14 in the above-described posture, the number of bend holes provided in the molding die can be greatly reduced as compared with the related art. Stem marks and vent debris generated at positions corresponding to the bend holes in the seat pad will be significantly reduced.

FIG. 3 shows another foaming mold that can be used for carrying out the present invention. FIG. 3 (a) shows two pillars 21 having one end connected to a pivot 12 and embedded in a seat pad. The mounting frame 22 is detachably mounted via a support pin 23, and FIG.
22 is mounted detachably via a support pin 24. In the molding die shown in FIG. 3 (b), the rotation angle of the support pin 24 and thus the pivot 12 to which the support pin 24 is fixed is
The mold closing posture can be appropriately selected by specifying the hook provided with the hole provided therein or the like.

Since molding by these molding dies can be performed in the same manner as described above, they can also provide the same operation and effects as in the above-described example.
After the completion of the molding, a seat cushion in which the embedding frame 22 is embedded at the boundary between the two types of foam materials having different characteristics can be provided.

(Effects of the Invention) Thus, according to the present invention, it is possible to manufacture a foamed product made of two different types of foamed materials at low cost with a small number of man-hours, and the appearance quality and cushion performance of the foamed product. Can be remarkably improved, and products having the same inner and outer qualities can be repeatedly produced.

[Brief description of the drawings]

FIG. 1 is a perspective view illustrating a foaming mold that can be used in carrying out the present invention, FIG. 2 is a view illustrating a mold closing posture of the mold, and FIG. 3 is used in carrying out the present invention. FIGS. 4 and 5 are cross-sectional views illustrating a conventional method, respectively. 11 ... Base, 12 ... Axis 13 ... Front type, 14 ... Back type

Claims (1)

(57) [Claims] 1. A front mold and a rear face which are opened substantially horizontally when a foaming product is formed by a foam mold comprising a front mold for molding a front part of a foamed product and a rear mold for molding a back part thereof. Inject or spray each of the different types of foaming liquid on each molding surface of the mold to foam it. At the timing of 30 to 100% of the rise time of the lately supplied foaming liquid, move the front mold and back mold from the horizontal plane. A foam molding method, wherein the mold is closed in a posture facing upward.