JP2763574B2 - Manufacturing method of integral foam sheet - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for manufacturing an integral foam sheet in which a main pad is integrally foam-molded on a lower surface side of a skin material.

[Prior Art] Conventionally, for example, in order to emphasize the luxury of the design of a vehicle seat 1, as shown in FIG. 9, a seat cushion 2 of a seat 1 and a seat surface portion and a back contact portion of a seat back 3 as shown in FIG. There is one in which narrowing recesses 4 are provided at predetermined intervals on the surface and formed in a substantially cushion-like style. As a first means for forming the narrowing recesses 4, a seat cushion pad as shown in FIGS. A hole 6 penetrates through a portion forming the narrowing recess 4 on the side 5, and a hole 10 corresponding to the hole 6 penetrating through the seat cushion pad 5 is formed in a skin material 7 composed of a skin 8 and a cover pad 9. The apertures 6, 10 are aligned and the aperture member 11 forms the aperture recess 4. The squeezing member 11 is composed of two members, a button 12 and a button retainer 13. The button 12 has a head 12a having a predetermined diameter, and a shaft portion from the center of the head 12a.
A substantially warhead-shaped locking portion 12c is integrally formed at the tip of the coaxial portion 12b. Also, button retainer 1
3 is formed in a disk shape having a predetermined diameter, and a hole 13a having a diameter capable of locking the button 12 is penetrated in a central portion thereof, and a slit groove 13b is formed in a direction orthogonal to the hole 13a. Each piece 13c is provided so as to be elastically displaceable. The button 12 provided in this manner is inserted into the holes 6 and 10 to make the skin material 7 in a squeezed shape, and the retainer 13 is locked on the back side to form the squeezed concave portion 4. As a second means, as shown in FIG. 12, the skin material 7 is squeezed in a pressing manner and sewn with a sewing machine 14 or the like to form a squeezed recess 4.

[Problems to be Solved by the Invention] However, this first means requires a step of drilling holes 6 and 10, increases the number of parts of the narrowing member 11, requires a management step, and requires a large number of assembly steps. Become
There is a problem that the button 12 gives a foreign-body sensation when seated, and in the second means, the narrowing-down depth of the narrowing-down recess 4 becomes small due to the rigidity of the back surface of the seat cushion pad 5 and the unevenness is expressed. Is difficult to express conspicuously, looks bad in terms of luxury and requires considerable skill,
There was a problem that many man-hours were required.

The present invention has been made in order to solve the above-mentioned conventional problems, and it is possible to easily form a narrowed concave portion in a sheet forming process, to eliminate a feeling of foreign matter at the time of sitting, and to reduce unevenness of the seat surface. It is an object of the present invention to provide a method for producing an integral foamed sheet that can be remarkably expressed.

Means for Solving the Problems In order to solve the above-mentioned technical problems, the present invention provides a main pad formed by integral foam molding on a back surface side of a skin material forming a seat surface portion of a seat cushion and a back contact portion of a seat back. Are laminated and formed into a predetermined portion on the skin material side of the seat surface portion or the back contact portion to form a concave portion. In the integrated foam sheet, the die surface for forming the seat surface portion and the back contact portion of the foam molding die is subjected to the narrowing. A squeezing projection having a shape and height corresponding to the squeezing recess is formed at a portion where the recess is to be formed, and the skin material is tightly wrapped around the squeezing projection to form a squeezing portion. Attach an elastic ring to the part, under this, inject a foaming agent into the foaming mold,
This is a method for manufacturing an integral foam sheet having a configuration in which after the mold is closed, the foaming agent is foamed and cured to narrow down the seat surface portion and the back contact portion to form a concave portion.

Example (First Example) Next, a first example of the present invention will be described with reference to FIGS. 1 to 5. In the present example, the seat cushion 22 and the seat In order to form a luxurious sheet by forming narrow recesses 24 in the seating surface and back contact portion of the back 23 to express the unevenness conspicuously, a molding die 25 is used for combining the upper mold 26 and the lower mold 27. It is provided in the mold. For example, a mold surface 28 for molding the seat cushion 22 is provided in the lower mold 27, and a bottom portion 29 of the mold surface 28 (on the front side of the seat cushion 22) is provided with a predetermined portion in a portion for forming the narrowing recess 24. A narrowing convex portion 30 of a predetermined height having a substantially inverted funnel shape and a rounded upper end formed at intervals, and a concave groove 22a connecting between the narrowing concave portions 24 of the seat cushion 22 between the convex portions 30. Is formed to have a chevron-shaped ridge 31 for recessing. The skin material 7 set on the lower mold 27 thus formed is formed by bonding or heat-sealing a cover pad (slab urethane) to the skin (fabric) as in the conventional case. The skin material 7 is placed along the mold surface 28 of the lower mold 27. And isomorphic
A narrowing portion 7a is formed so as to be in close contact with the narrowing convex portion 30 protrudingly formed at 28 so that the skin material 7 is in close contact therewith. Thereafter, an elastic ring 32 for tightening and fixing the narrowed portion 7a along the convex portion 24 is elastically attached.

The elastic ring 32 is formed of, for example, an O-ring having a predetermined diameter by using an elastic synthetic resin, synthetic rubber, or the like, or a coil-shaped O-ring. In addition to the elasticity of fixing the narrowed portion 7a to the root portion of the above, the other portion of the skin material 7 is arranged so as to be in close contact with the ridges 31 formed between the narrowing convex portions 30 and the mold surface 28. When the setting of the skin material 7 is completed in this way, the foaming agent of the main pad 33 is injected into the mold of the lower mold 27, the upper mold 26 is closed and foamed and solidified, and the mold is opened to open the mold. 7 and main pad
Take out the molded sheet W into which 33 is integrated.

The formed sheet W thus obtained foamed and solidified the main pad 33 in a state where the squeezed portion 7a along the squeezed convex portion 30 was elastically attached by the elastic ring 32. It is molded into the concave portion 24 of a uniform shape, and the concave groove 22a is also molded in a state of being sufficiently adhered to the mountain-shaped ridge 31 by the foaming pressure of the foaming agent, and is molded into the target shape, It is possible to obtain a molded sheet W having a beautiful design.

The molded sheet W formed in this foam molding step is transferred to the next step, and is placed on a seat spring 34 attached to a seat frame as shown in FIG. It is formed.

The seat back 23 is formed in the same manner as described above.

Second Embodiment Next, a second embodiment of the present invention will be described with reference to FIGS. This second embodiment differs from the first embodiment in that a large number of narrowing recesses 24 are formed, as shown in FIG.
This is a case where one or a plurality of narrowing recesses 37 (in this example, a single case is illustrated) which are relatively long in the left-right direction of the seat surface portion and the back contact portion of 36 are formed. Along with the portion of the mold surface 39 of the lower die 38 of the molding die for molding the seat cushion 35 where the narrowing recess 37 is to be formed, a narrowing convex portion 40 having a predetermined height and a length commensurate with the concave portion 37 is provided. It is formed, and a root portion of the convex portion 40 is provided with an R portion. Therefore, also in the second embodiment, the skin material 7 is placed in the same manner as in the first embodiment, and the skin material 7 is formed with a narrowed portion 7b in close contact with the narrowing convex portion 40. As in the first embodiment, an elastic ring 41 is elastically attached to the outer periphery of the narrowed portion 7b. In this state, a foaming agent is injected into the lower mold 38, and then the mold is closed and foamed and solidified to form the narrowed recess 37. A concave formed sheet W can be obtained.

[Effects of the Invention] Since the present invention is configured as described above, it is possible to form a target narrowing concave portion on the seat surface portion and the back contact portion which are the seat surface, and furthermore, the convex concave portion is provided on the lower mold. Since it is a simple operation to make the skin material adhere to the narrowing projections and to elastically attach the elastic ring, there is no need for skilled personnel, the number of man-hours can be reduced, and stable shape quality molding The seat can be obtained, and the feeling of foreign objects at the time of sitting can be eliminated.

[Brief description of the drawings]

1 to 5 show a first embodiment of the present invention.
Fig. 2 is a perspective view of the sheet, Fig. 2 is a schematic sectional view of a molded sheet placed on a sheet frame, Fig. 3 is a sectional view of a molding die combined, and Fig. 4 is a lower mold with a skin material. FIG. 5 is a perspective view showing a state in which an elastic ring is elastically attached to the narrowing projection, and FIGS. 6 to 8 show a second embodiment of the present invention. FIG. 6 is a perspective view of the sheet, FIG. 7 is a partially broken perspective view when a skin material is set on the lower mold, FIG. 8 is a perspective view showing a state in which an elastic ring is elastically attached to the narrowing projection, and FIG. 9 to 12 show a conventional example. …… Skin material 7a, 7b …… Drawing part 22,35 …… Seat cushion 23,36 …… Seat back 24,37 …… Drawing recess 27,38 …… Lower mold 28,39 …… Mold surface 30,40 …… Narrowing down projection 32,41 …… Elastic ring 33 …… Main pad

Claims (1)

(57) [Claims] 1. A main pad is laminated by integral foam molding on a back surface side of a seat material forming a seat surface portion of a seat cushion and a back contact portion of a seat back, and a main pad is laminated on the back surface side of the seat surface portion or the back contact portion. In an integrated foam sheet for forming a narrowed concave portion at a predetermined location, a mold surface for forming the narrowed concave portion is formed on a mold surface for forming the seating surface portion and the back contact portion of a foaming mold. A convex portion is provided, and the skin material is closely adhered to the narrowing convex portion to form a narrowed portion, and an elastic ring is elastically attached to the narrowed portion.
Injecting a foaming agent into a foaming mold, closing the mold, and then foaming and curing the foaming agent to narrow down the seating surface and the back contact portion to form a concave portion. Method.