JP3434062B2 - Method for producing foam molded article and foam molding die thereof - 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 molded article having an insert wire for a hog ring and a foam molding die for the same.

[0002]

2. Description of the Related Art Vehicle seats and the like are often used in which a foam molded article is covered with a seat cover which is a skin material such as a fabric. Hog rings have generally been used to attach seat covers of this type. This is to fix the wire inserted into the end portion of the seat cover and the insert wire embedded in the foam molded body with a C-shaped wire clip.

FIG. 7 shows a seat pad 4 used on the seat back side of a rear seat as an example of a foamed molded product provided with an insert wire. In the figure, on the back surface of the seat pad 4 and on the bottom surface (top surface of FIG. 7) of the bank 43,
The insert wire 3 is embedded along the long side. The insert wire 3 is exposed in the recesses 44 formed at two locations in the longitudinal direction of the bottom surface of the bank (FIG. 8 shows an enlarged view of the periphery of the recess 44). The cover is fixed. Insert wire 3
Is a terminal folded back in a loop at a position near the recess 44 after passing through the recess 44. This is because the use of the folded-back end 31 ensures the holding of the insert wire 3 and ensures safety.

The seat pad 4 provided with such an insert wire 3 has been conventionally manufactured by using a foam molding die as shown in FIGS. 9 to 11. FIG. 9 is a partial vertical cross-sectional view of an upper mold 1 according to a conventional foaming mold. In the upper mold 1, a part of a mold surface 1a projects downward in a trapezoidal shape to form a support portion 11.
The previously described recess 44 of the seat pad 4 is made by the support 11. The magnet 13 is embedded in the support portion 11 and has a structure in which the insert wire 3 made of metal is attracted to the support portion 11 by magnetic force and can be held in the cavity. In order to prevent the positional deviation of the insert wire 3, it is preferable that the insert wire 3 be close to the surface of the seat pad, and it is preferable from the viewpoint of workability of attaching the hog ring. Therefore, the degree of protrusion of the support portion 11 is small, and in many cases, the loop-shaped folded end 31 of the insert wire 3 is provided close to the upper mold surface 1a. By the way, the seat pad 4 has a foamed resin material such as urethane (hereinafter referred to as “foamed material”) in a cavity holding the insert wire 3.
Is obtained by foaming, but the direction of travel of the injected foaming raw material is from downward to upward, as indicated by the arrow in FIG. For this reason, as described above, when the loop-shaped folded end 31 of the insert wire 3 is disposed close to the support portion 11, the flow of the foaming raw material is poor at this portion, and foam molding is likely to be hindered. It was As a result, as shown in FIG. 10, in the area adjacent to the support portion 11 where the folded end 31 of the insert wire 3 is located, air stayed near the surface of the foam-molded seat pad 4 and an air pocket P was generated. FIG. 11 shows the entire cross section of the foaming mold, but the air pockets P tend to be easily formed in the region above the folding end 31 of the insert wire 3 buried near the top surface of the seat pad 4 having a substantially L cross section. there were. The air pocket P not only creates a hollow portion to make it look unattractive, but also weakens the holding force of the insert wire 3.

For this reason, the conventionally-released seat pad 4
The air pocket P of the above is removed in a concave shape (reference numeral 4 in FIG. 12).
5) As shown in FIG. 13, a slab 46 having substantially the same shape as the removed air pocket P has been embedded therein, and a non-woven fabric 47 or the like has been attached to the slab 46 to repair it.

[0006]

However, the post-processing such as removing the air pocket in a concave shape, filling it with a slab, and further pasting a non-woven fabric is troublesome and time-consuming, and the labor load required for correcting the seat pad is large. It was.

The present invention solves the above-mentioned problems, and in the production of a foamed molded article having an insert wire,
An object of the present invention is to provide a method for producing a foamed molded product and a foamed molding die thereof, which enables efficient production without the need for post-processing.

[0008]

The gist of the first aspect of the present invention is to provide a support part which is formed so as to partially project from the mold surface of the upper mold to hold the insert wire for hog ring in the cavity, and an area adjacent to the support part. A foam molding die having an air pocket guiding portion formed in a concave shape on the upper mold surface is used to hold the insert wire in the support portion, and then a foam resin raw material is injected into the cavity to perform foam molding. After the completion, a method for producing a foamed molded product, characterized in that the foamed raw material is intruded into the air pocket guiding part to remove the formed protruding part so as to be flush with a general surface to obtain a foamed molded product. is there. The gist of the second aspect of the present invention is to provide a support portion that is formed so as to partially project from the mold surface of the upper mold to hold the insert wire for hog ring in the cavity, and the loop-shaped folded end of the insert wire to be held is positioned. In the foam molding die of the foam molded article, an air pocket guide portion is formed by recessing a predetermined amount on the upper mold surface of the area adjacent to the support portion.

[0009]

According to the method for producing a foamed molded article and the foaming mold, the foaming raw material injected into the cavity is foamed upward from the lower point toward the loop-shaped folded end of the insert wire. The raw material flow is obstructed. Therefore, the air above the insert wire does not escape to the outside of the mold, and an air pocket is generated (as in the conventional case). However, when the air pocket guide portion is formed as in the present invention, the air is guided into the air pocket guide portion, and
Since the specific gravity of the air that has entered the air pocket guide portion is smaller than that of the foaming raw material, the air gradually rises in the air pocket guide portion as the foaming raw material enters and gathers near the top of the molded protrusion. Therefore, after the foam molding, if the protrusion formed by the air pocket guide portion is removed so as to be flush with the general surface of the foam molded body, the air pocket is also removed together. The protrusion can be easily removed along the general surface by using a cutter or the like, and post-processing after foam molding is greatly reduced.

[0010]

EXAMPLES The present invention will be described in detail below based on examples.
1 to 6 show an embodiment of a method for producing a foam molded article and a foam molding die thereof according to the present invention. 1 is a partially enlarged vertical sectional view of a foaming mold immediately after molding, which is a sectional view taken along the line I-I of FIG. FIG. 2 is an overall cross-sectional view of the foaming mold immediately after molding, FIG. 3 is a cross-sectional view of the seat pad, and III-II of FIG.
It is sectional drawing which follows the I line. 4 is a perspective view of the entire back surface of the seat pad immediately after the mold is removed, FIG. 5 is an enlarged cross-sectional view of an essential part of the seat pad of FIG. 4, and FIG. 6 is a perspective view of the entire back surface of the seat pad after the protruding portion is cut off. It is applied to a seat pad on the rear seat back side as a foamed molded body.

The foam mold comprises an upper mold 1 and a lower mold 2,
The cavity of the seat pad 4 is created by closing the mold. On a mold surface 1a that forms a cavity of the upper mold 1, a support portion 11 that partially projects downward in a trapezoidal shape is formed (FIG. 1). The support portion 11 has a magnet 13 embedded therein so that one end of the insert wire 3 can be attracted and held. The end 31 of the insert wire 3 is folded back in a loop shape in the vicinity of the support portion. The height of the support 11 is about 12 mm. The dimensions are set from the viewpoint of workability of the hog ring and prevention of misalignment. Reference numeral 12 indicates an air pocket guide portion provided in an area adjacent to the support portion 11 on which the loop-shaped folded end 31 is arranged. The upper mold 1 is formed by recessing upward in a rectangular shape on the mold surface 1a. Due to the formation of the air pocket guide portion 12, only in this portion, the parting line rises from the conventional position.

The foaming mold is one in which the supporting portion 11 and the air pocket guiding portion 12 are formed at two locations in the longitudinal direction of the upper die 1, and both end portions of the linear insert wire 3 are sucked and held by the supporting portion 11. You can do it. After the upper mold 1 and the lower mold 2 are closed, a foaming raw material is injected and foam molding is performed to form a sheet pad 4 as a foam molded body. In FIG. 2, reference numeral 4
2 indicates a core material (insert).

The manufacture of the seat pad 4 using the foaming mold is as follows. First, the foam molding die is opened and the core material is set in the lower die 2. Further, the insert wire 3 is held on the support portion 11 of the upper mold 1 by magnetic attraction. Then, after pouring a foaming raw material such as a urethane foam raw material into the cavity, the mold is closed and the process proceeds to foam molding.

In the foam molding process, the foaming direction of the foaming raw material goes from the lower part to the upper part. In the region where the loop-shaped folded end 31 of the insert wire 3 is located, the flow of the foaming raw material is obstructed and air stays, but this air is taken into the air pocket guide portion 12. Since the specific gravity of air is smaller than that of the foaming raw material, the air gradually rises in the air pocket guide portion 12 as the foaming raw material enters. As shown in FIG. 1, air gathers near the bottom of the air pocket guide 12, that is, near the top of the protrusion 41 of the seat pad 4 formed by the foaming raw material that has entered the air pocket guide 12.

After the foam molding is completed, the mold is opened and the seat pad 4 (foam molded body) is taken out. As shown in FIG. 4, the taken-out seat pad 4 has an insert wire 3 embedded along the long side in the vicinity of the bottom surface of the bank 43 of the seat pad 4. The insert wire 3 is exposed in the recesses 44 formed at two locations in the longitudinal direction by the support portion 11 of the upper mold 1. Adjacent to the recesses 44, the air pocket guide portions 12 of the upper mold 1 respectively form the protrusions 41, 41, and the air pockets P are formed near the top of the protrusion 41 as described above ( (Figure 3).

After that, the protruding portion 41 is cut by the cutter 5 so as to be flush with the general surface 4a of the seat pad to obtain a final product. By cutting the cutter 5 (FIG. 4), the air pocket P is also removed from the final product together with the protrusion 41. Here, cutting of the protruding portion 41 is performed by cutting the seat pad 4 as shown in FIG.
It suffices to move the cutter 5 flush with the general surface 4a of (1) (chain line in the figure), and it can be easily performed without using a guide jig or the like of the cutter 5. FIG. 6 shows an external appearance of the seat pad 4 after the protruding portion 41 is cut off. Non-woven fabric attached 4
7 (FIG. 7) has been eliminated, and the pad material of the same quality has a continuous appearance.

In the method for producing a foam molded article and the foam molding die thereof according to the above-described aspect, the air pocket guide portion 12 is formed, and the hard-to-remove air around the folding end 31 is positively guided into the air pocket guide portion 12. Then, the trouble caused by the air pocket generation is solved. Until now, the insert wire 3 held by the support portion 11 was arranged at a position close to the upper mold surface 1a, which hindered the flow of the foaming raw material and caused air pockets. Since 12 is provided in the area adjacent to the support portion 11 where the air pocket can be formed,
The air that creates the air pocket is stored in the air pocket guide 12 without difficulty. Further, since the protrusion 41 formed by the air pocket guide portion 12 by foam molding has a form partially protruding from the general surface 4a, the protrusion 41 can be easily cut so as to be flush with the general surface 4a. Here, since the air introduced into the air pocket guide portion 12 is lighter than the foaming raw material, it goes upward in the air pocket guide portion 12,
It will accumulate above. Therefore, the air pocket-influenced portion appears only on the upper portion of the protruding portion 41, and the air pocket portion that causes a problem can be removed by cutting off the protruding portion 41.

In this way, the post-processing is completed only by cutting the protruding portion 41, so that the post-processing work is shortened. Further, since the projecting portion 41 can be cut along the general surface 4a (product surface), the work becomes easier. Furthermore, the protruding portion 41
Since the air pocket where the material is fragile is eliminated by the cut, the removal strength of the insert wire 3 is improved, and the absence of the air pocket prevents the occurrence of wrinkles due to the skin material entering the air pocket portion. It became so.

The present invention is not limited to those shown in the above embodiment, but can be variously modified within the scope of the present invention depending on the purpose and application. The number, size, shape, material and the like of the support portion 11, the air pocket guide portion 12, the insert wire and the like can be appropriately selected. Not limited to seat pads for automobiles, it can be widely applied, and in that case, it can be variously changed according to the purpose of use, required strength, use, etc. of the product.

[0020]

INDUSTRIAL APPLICABILITY As described above, the method for producing a foam molded article and the foam molding die of the present invention can easily remove the air pockets produced by foam molding without impairing the appearance, and reduce post-processes. This is advantageous because it is possible to achieve both improvement of manufacturing efficiency due to and reliable holding of the insert wire for hog rings.

[Brief description of drawings]

FIG. 1 is a partially enlarged vertical cross-sectional view of a foaming mold immediately after molding according to an embodiment of the present invention, which is a cross-sectional view taken along line I-I of FIG.

FIG. 2 is an overall cross-sectional view of a foam molding die immediately after molding.

3 is a cross-sectional view of the seat pad, which is taken along line III-III of FIG.
It is sectional drawing which follows the line.

FIG. 4 is a perspective view of the entire back surface of the seat pad immediately after demolding.

5 is an enlarged cross-sectional view of a main part of the seat pad of FIG.

FIG. 6 is a perspective view of the entire back surface of the seat pad after the protrusion is removed.

FIG. 7 is a perspective view of the entire back surface of a conventional seat pad.

8 is an enlarged perspective view of a main part of the seat pad, which is an enlarged view of a portion A in FIG. 7.

FIG. 9 is a partially enlarged vertical sectional view of a conventional foaming mold before molding.

10 is a partially enlarged vertical sectional view of a conventional foaming mold immediately after molding, which is a sectional view taken along line XX of FIG.

FIG. 11 is an overall cross-sectional view of a conventional foaming mold immediately after molding.

12 is a cross-sectional view of the seat pad after removal of air pockets, which is a cross-sectional view taken along line XII-XII of FIG.

FIG. 13 is an exploded perspective view of the seat pad after the air pocket is removed.

[Explanation of symbols]

1 Upper mold 1a Upper mold surface (mold surface) 11 Support 12 Air pocket guide 2 Lower mold 3 insert wire 31 Folded end 4 Seat pad (foam molding) 4a General surface 41 Projection

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI B29L 31:58 B29L 31:58 (72) Inventor Kazuhisa Ando 3-36 Imaikecho, Anjo City, Aichi Prefecture Inoac Corporation Anjo Plant (56) References JP-A-4-89222 (JP, A) JP-A-5-309674 (JP, A) Fukuihei 2-112197 (JP, U) (58) Fields investigated (Int .Cl. ⁷ , DB name) B29C 39/00-39/44 B29C 33/00-33/76

Claims (2)

(57) [Claims] 1. A support part which is formed so as to partially project from the mold surface of the upper mold and holds an insert wire for hog ring in a cavity, and an air pocket which is formed in a recess in the upper mold surface located in an area adjacent to the support part. A foam molding die having a guide part is used to hold the insert wire in the support part, and then a foam resin material is injected into the cavity to complete foam molding, and then the foam pocket material is supplied to the air pocket guide part. A method for producing a foamed molded product, characterized in that a protruding part formed by invading is removed so as to be flush with a general surface to obtain a foamed molded product. 2. A support part which is formed so as to partially project from the mold surface of the upper mold to hold the insert wire for hog ring in the cavity, and the support where the loop-shaped folded end of the insert wire to be held is located. A foam molding die for a foam molded article, wherein an air pocket guide portion is formed by recessing a predetermined amount in an upper mold surface of a region adjacent to the portion.