JP2847647B2 - Manufacturing method of integrated foam with integrated insert - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a foam product with a built-in insert and a skin, which does not require any post-treatment or the like and has a good finish.

[0002]

2. Description of the Related Art In a headrest, an armrest, and the like of an automobile, a foam integrated with a built-in skin, which is obtained by injecting a foaming material into a skin on which an insert is provided and foaming the foam integrally with the skin, the insert, is widely used. Conventionally, two methods have been used for the production of such a foam product with a built-in insert skin, due to the difference in the injection method of the foaming raw material. One is a method in which an injection port 15 formed of a circular hole or the like is formed in the skin 1 as shown in FIG. 9 and a foaming material 31 is injected into the injection port 15 with a funnel 7 or the like (prior art 1). The other is a method of providing a slit-like opening 11 also serving as an insert for the insert 2 in the epidermis 1 as shown in FIG. 10, and expanding the opening 11 to inject the foaming raw material 31 into the epidermis. (Prior Art 2).

[0003]

However, there have been problems with any of the conventional methods. Once the injection port 15 of the prior art 1 is completed as a product, the internal foam
And the appearance was bad (Fig. 11). For this reason, the covering cloth 9 is sewn to the epidermis 1 in advance so that the filling port 15 is hidden, and the filling port 9 is covered with the covering cloth 9 using an adhesive or the like. However, not only a post-process such as bonding and fixing was necessary, but also troubles of poor bonding occurred frequently.

On the other hand, according to the prior art 2, when the opening 11 is opened to inject the foaming material, the skin 1
Was often soiled. In order to open the opening 11 widely, the set state of the epidermis 1 becomes unstable,
Problems such as formation of wrinkles and meandering of the slit-shaped opening 11 on the product surface have appeared. Also, the opening 11
Because of the large cut edge, the skin 1 hangs down into the cavity 64 due to the weight of the skin itself. Furthermore,
There is also a disadvantage that the opening 11 of the large mouth has no sealing function, and the foaming raw material 31 injected into the epidermis leaks out of the opening 11 due to the foaming pressure.

[0005] In order to improve such disadvantages, for example, the invention of Japanese Patent Application Laid-Open No. 4-279307 has been proposed. However, only the skin stain is improved, and the defect that the elongated slit-shaped opening 11 meanders on the product surface still remains and impairs the product appearance. As a result, the quality of the product was reduced.

The present invention solves the above-mentioned problems, and does not require any post-treatment and the like, and the opening on the product surface is finished in a clean state of a single character while preventing the foaming material from adhering to the skin. An object of the present invention is to provide a method for producing a foamed product with a built-in insert and a skin.

[0007]

According to the present invention, there is provided a method for producing a foamed product with a built-in insert-integrated skin, wherein an insert is disposed in the skin of a bag-like skin forming a slit-shaped opening, and the insert and the skin are foam-molded. After setting in a mold, a foaming material is injected into the epidermis from the above-mentioned opening, and foaming is performed integrally with the epidermis and the insert. a pair of tongues to extend the edge, tongue with sandwiching the tubular film to pieces, tongue pieces to insert the plate-shaped jig openings length substantially equal to the length to the plate-shaped jig The lower end of the tongue inside
After stretching the opening straight with a plate jig by setting it down , insert a funnel into the tubular film and inject foaming material into the epidermis through the funnel, or Jo film foaming material crowded difference the injection nozzle of the foaming material into the injection into the skin, have rows foam molding, the
Thereafter, the plate jig is extracted from between the tongue pieces .

Here, "a pair of tongue pieces" means a tongue piece that is divided into two pieces with an opening therebetween. The tongue piece is simply divided into two or more pieces. It also includes one in which the side has a cylindrical shape by suturing or the like. In "inserting a tubular film between the tongue pieces and inserting a plate-like jig having a length substantially equal to the length of the opening between the tongue pieces," either the tubular film or the plate-like jig is inserted between the tongue pieces. It does not matter whether or not it is arranged in preference to. Of course, the case where the tube-shaped film and the plate-shaped jig are arranged together between the tongue pieces may be used.

[0009]

According to the method for producing a foam with a built-in epidermis according to the present invention, when the plate-shaped jig is inserted between the tongue pieces, the plate-shaped jig makes the opening straight and tight. Then, when the tube opening (or injection nozzle) of the funnel is inserted into the tubular film sandwiched between the openings and the foaming material is poured into the funnel (or injection nozzle), the foaming material is injected into the epidermis without soiling the epidermis. it can. When the funnel (or the injection nozzle) is withdrawn after the injection of the foaming raw material, the trace of the tube opening (or the injection nozzle) of the funnel disappears by the plate-shaped jig, and the opening maintains the state of a single letter again. Thus, when foam molding is performed,
When the plate-shaped jig stretches the opening, the tongue pieces come into close contact with each other, and the foaming material does not leak from the opening due to the foaming pressure. After the foam molding, the plate jig and the tube-shaped film are removed from the skin, and since the thickness of the plate jig and the tube-shaped film are both thin, these traces disappear cleanly due to the residual foaming pressure of the foaming material, and the opening is formed. Thus, the finished surface is straight and straight with slit lines on the product surface.

[0010]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail based on embodiments. (1) Example 1 FIGS. 1 to 7 show one example of a method for producing a foam product with a built-in insert and a skin according to the present invention. A fixed headrest is made. 1 is an exploded perspective view of a plate jig before the plate jig is inserted into a skin, FIG. 2 is a cross-sectional view taken along line XX of FIG. 1, FIG. 3 is an enlarged perspective view of the plate jig, and FIG. FIG. 5 is a cross-sectional view showing the state of the skin and the plate jig after foam molding is completed, and FIG. 6 is a state in which the skin is set in a foam molding die and a foaming material is injected into the skin. FIG. 7 is a perspective view of a headrest that has become a product.

[0011] The headrest, which is a foamed product A with a built-in skin and an insert, comprises a skin 1, an insert 2, and a foam material 31.
And a foam material 32 formed by foaming and curing. Epidermis 1
Is made of hard vinyl chloride and formed into a predetermined bag shape by slush molding. In addition to the above components, the tubular film 4 is used to prevent the adhesion of the foaming raw material 31, and the plate jig 5 is used as a correction tool (FIG. 1). The foaming mold 6 includes a base die 61 and a lid die 62, and the base die 61 and the lid die 62 form a product-shaped cavity 64.
Reference numeral 63 indicates a hinge, and the lid mold 62 can be freely opened and closed with respect to the base mold 61.

Prior to manufacturing the headrest, the tubular film 4 is mounted in the opening 11 of the skin 1. The tubular film 4 is made of polyethylene. The tubular film 4 may be formed in a cylindrical shape in advance, or may be a commercially available polyethylene bag having an opened bottom. The opening 11 is provided in a slit shape at a position to be the bottom of the skin 1. The slit length of the opening 11 is elongated in order to easily store an insert 2 described later in the skin 1.
In the opening 11, the opposing skin edges are extended and bent into the skin to form a pair of tongue pieces 12, 12 (FIG. 2). The tubular film 4 is sewn to one of the tongue pieces 12 so that the tubular mouth is opened. Tubular film 4
The upper side protrudes about 2 cm from the skin bottom 13. Further, the lower side of the tubular film 4 is kept in the tongue piece 12. After these preparations, the headrest will be manufactured.

[0013] The headrest is manufactured by first opening the opening 11.
Insert 2 into the epidermis 1 from the
The process starts with the insert 2 being placed in the epidermis such that 1 protrudes from the insertion holes 14 and 14 (FIG. 1).
Next, the plate jig 5 is inserted between the tongue pieces 12 and 12 in the opening 11.
Plug in.

Here, the plate-shaped jig 5 is formed by welding bent plates 52, 52 to both sides of a support portion 51 as shown in FIG. The support portion 51 has a concave groove 511. Funnel 7
This is for guiding the cylinder opening 71 of the cylinder. The bending plate 52 is made of a thin iron plate having a thickness of about 1.2 mm, and has a fixed portion 521 and a functional portion 5.
22. The fixed part 521 and the function part 522 are
It is in a state of being bent at an angle of about 20 degrees in the shape of a "ku" (FIG. 4). The function part 522 has an elongated plate shape, and its total length L is
It is made slightly longer than the slit length of the opening 11. Therefore, when the functional portion 522 is inserted between the tongue pieces 12, 12, the functional portion 522 causes the opening 11 to be in a straightened state in a straight line.

When the plate jig 5 is inserted, the jig 5 is inserted until the opening edge of the skin 1 enters the cutout grooves 5221 and 5221 provided on both side edges of the functional portion 522. Plate jig 5
Is locked to the epidermis 1 and does not easily slip. The plate-shaped jig 5 has the tongue pieces 12, 12
When set between the tongues 12,
It stays in the tongue piece 12 without protruding. Then, the inserted plate-like jig 5 is attached to the lower part 121 of the tongue piece 12,
121 are brought into close contact with each other (see FIG. 5).

Next, the skin 1 on which the tubular film 4, insert 2, and plate jig 5 are arranged is set in a foaming mold 6 (FIG. 6). Here, the positioning hole 5211 of the plate-shaped jig 5 is fitted into a small projection (not shown) of the lid mold 62, so that the plate-shaped jig 5 is easily and accurately set on the lid mold 62. A magnetic body (not shown) is embedded in the lid mold 62, and has a configuration in which the fixing portion 521 is magnetically attracted.
This is for stably holding the plate jig 5 on the base die 61. The skin 1 is also conveniently stored in the cavity 64.

Subsequently, the funnel 7 is inserted into the concave groove 511 of the plate jig 5.
The tip of the cylinder mouth is inserted into the tubular film 4 while applying the cylinder mouth 71 of FIG. By sliding the barrel opening 71, the tip of the barrel opening 71 is finally disposed in the opening 11. Then, by closing the foaming mold 6, preparation for injecting the foaming raw material is completed.

After the above operation, the foaming raw material 3
Inject 1. A predetermined amount of the foaming raw material 31 is injected into the epidermis 1 from the injection machine 8 via the funnel 7 (FIG. 6). In the process of injecting the foaming raw material 31, even if the foaming raw material 31 hangs down from the funnel 7, the operation is performed with the mold closed, so that the skin 1 is not stained. Further, since the tubular opening 71 is covered with the tubular film 4, even if the vicinity of the tubular opening 71 is soiled by the foaming raw material 31, the tubular film 4 protects and prevents the foaming raw material 31 from adhering around the opening 11. Preventing.

When the injection of the foaming raw material 31 is completed, the funnel 7 is immediately removed. This is because the opening 11 is again stretched in a straight line by the plate jig 5, and the opening 11 is sealed by the close contact between the tongue pieces 12, 12. By the way, as soon as the funnel 7 passes, the trace of the tube opening 71 disappears. Further, even if the drops of the foaming raw material 31 hang down when the funnel 7 is withdrawn, the foaming raw material 31 is accommodated in the tubular film 4,
Does not adhere to In the present embodiment, the foaming raw material 31 is injected into the skin 1 via the funnel 7, but the injection nozzle of the foaming raw material 31 may be directly inserted into the tubular film 4 without passing through the funnel 7. Foaming raw material 31 to skin 1
It is because it can be injected into. The injection nozzle may be one that forms a part of the main body of the injector 8 or one that is connected to the injector 8.

Then, the process proceeds to the next foam hardening step. In the foam hardening process, the opening 11 is already in a state where the opening of the opening 11 is closed by the plate-shaped jig 5. Accordingly, the opening 11 is more strongly closed. Foam material 3
2 is to fill the cavity by tightening the tongue pieces 12 and 12 from both sides so as to close the opening 11 and prevent the foam material 32 from leaking to the surface of the skin. In particular, the configuration in which the tongue piece lower portions 121 are in close contact with each other prevents the foaming raw material 31 from leaking further (FIG. 5).

When the foaming and hardening are completed, the process enters a product release process. After removing the mold, the plate jig 5 and the tubular film 4 are removed from the opening 11. Thus, a headrest as a foam product A with a skin integrated with an insert is completed.

In the headrest produced in this manner, the plate jig 5 and the tubular film 4 are both thin, so that the traces extracted from the opening 11 form the foam material 3.
It disappears neatly due to the residual foaming pressure of 2. Then, the tongue piece 12 is moved by the plate jig 5 so that the opening 11
It is surely bent at about 90 degrees from the surrounding outer skin 1, and the opening 11 is finished in a neat state in which it is closed in a straight line (FIG. 7). As before, the opening 1
There is no defect in which the slit 1 meanders or undulates, and the periphery of the slit hangs down into the epidermis. This is because the plate-shaped jig 5 finishes the foam molding under the state where the opening 11 is tightened, so that there is no room for the defect to enter.

Further, the foaming raw material 31 is injected through the funnel 7 after the mold is closed, and the cylindrical opening 71 is inserted into the tubular film 4.
Do not pollute. Even when the funnel 7 is pulled out, the foaming raw material 31 dripping from the funnel 7 is contained in the tubular film 4. In addition, since the plate-shaped jig 5 is inserted between the tongue pieces 12 and 12 to stretch the opening portion 11 and the lower part 121 of the tongue piece is formed by foaming, the tongue piece 12 is formed. It exerts a sealing function, and the foaming raw material 31 does not leak from the opening 11 to the surface of the skin during foam molding.

On the other hand, the plate jig 5 used in this embodiment has good operability and does not impose a labor burden. Since the concave groove 511 of the plate jig 5 also serves as a guide for the funnel 7, the funnel 7 can be easily inserted. Furthermore, since the plate jig 5 can be fixed to the lid mold 62, the setability of the skin 1 to the foam molding mold 6 is improved. Further, after the foam molding, the opening 11 is in a beautiful closed state, so that there is no need for post-processing to cover with a covering cloth or the like, which leads to a reduction in the number of working steps.

(2) Embodiment 2 In this embodiment, a plate jig 5 'as shown in FIG. 8 is used instead of the plate jig 5 of the first embodiment. Long functional section 52
Two wedge-shaped projections 5221, 5221 are formed on the lower edge of the two. The protrusion 5221 is attached to the tubular film 4.
And inserting the plate-shaped jig 5 between the tongue pieces 12 while keeping the tubular film 4 locked. With this configuration, if the plate-shaped jig 5 'is set between the tongue pieces 12, 12, the tubular film 4 is automatically set. Therefore, the step of sewing the tubular film 4 to the skin 1 can be omitted, and the labor saving is further advanced from the first embodiment. Other configurations are the same as those of the first embodiment. Headrest manufacturing method is also skin 1
The operation is the same as that of the first embodiment, except that the operation of attaching the tubular film 4 in the opening 11 is eliminated.

It should be noted that the present invention is not limited to those shown in the above embodiments, but can be variously modified within the scope of the present invention depending on the purpose and application. For example, the shape, material, and the like of the skin 1, the insert 2, the foaming material 31, the tubular film 4, the plate jig 5, and the funnel 7 are not limited to the embodiments. And
It is widely applied not only to headrest products but also to foam products with integrated inserts. After the mold is closed, the funnel 7 can be inserted into the tubular film 4. After inserting the funnel 7 into the tubular film 4, the operation may be shifted to the operation of injecting the foaming raw material 31 before closing the mold. Further, a method may be adopted in which the foam molding is completed while the funnel 7 is inserted into the opening 11. If it is a trace of a small funnel 7, foam material 32
This is because it can be eliminated by the residual foaming pressure. of course,
Instead of using the funnel 7, an injection nozzle can be inserted into the tubular film 4 to inject the foaming raw material 31 into the skin.

[0027]

As described above, the method for producing a foam integrated with a built-in insert according to the present invention not only prevents meandering of the opening and leakage of the foaming material by a simple structure,
While preventing the foam material from sticking to the skin, without post-processing,
It has excellent effects in providing high quality products, such as being able to finish the openings on the product surface nicely and cleanly in a straight line.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view of a first embodiment before a plate jig is inserted into a skin.

FIG. 2 is a sectional view taken along line XX of FIG.

FIG. 3 is an enlarged perspective view of a plate jig according to the first embodiment.

FIG. 4 is a side view of the plate jig of FIG. 3;

FIG. 5 is a sectional view showing a state in which a plate-shaped jig has been inserted into the skin and foam molding has been completed.

FIG. 6 is a cross-sectional view of a foaming mold showing a state in which a foaming material is injected into a skin.

FIG. 7 is a perspective view of a headrest as a product.

FIG. 8 is a perspective view of a plate-shaped jig according to a second embodiment.

FIG. 9 is an explanatory sectional view of Conventional Technique 1.

FIG. 10 is an explanatory sectional view of a conventional technique 2.

FIG. 11 is a perspective view of a product manufactured by the related art 1.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Skin 11 Opening 12 Tongue piece 2 Insert 31 Foaming material 4 Tubular film 5 Plate jig 5 'Plate jig 6 Foaming mold 7 Funnel A Insert integrated skin foam

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI B29K 105: 20 B29L 31:58

Claims (1)

(57) [Claims] 1. An insert is arranged in a bag-shaped skin forming a slit-shaped opening, the insert and the skin are set in a foaming mold, and a foaming material is injected into the skin from the opening. A method for producing a foam with a built-in insert and a foam integrally formed with the skin and the insert, and a pair of tongues is provided by extending a skin edge from the opening to the inside of the skin and providing a pair of tongues between the tongues together sandwiching the tubular film is set Suffice the lower end of the plate-shaped jig in the tongues and insert the opening length substantially equal to the length of the plate-shaped jig in the tongue pieces
Foam after stretched straight openings in the plate-shaped jig, the foaming material through the funnel crowded difference funnel to the tubular film in injected into the epidermis, or the tubular film within by crowded difference the injection nozzle of raw foaming material is injected into the skin, have rows foam molding, after which the plate-shaped jig
A method for producing a foam product with a built-in insert and a skin, wherein the foam is integrated with a tongue piece .