JP3627929B2 - Manufacturing method of foam with integrated skin - Google Patents

Description

[0001]
[Industrial application fields]
The present invention relates to a method for manufacturing a foam integrated with a skin, which is used for manufacturing a headrest of an automobile seat and the like, in which a substantially bag-shaped skin is placed in a molding die and foamed resin is injected into the skin to perform foam molding.
[0002]
[Prior art]
The headrest of an automobile is formed from a foamed molded body having a core material inside and having a skin coated on the surface. As a method of manufacturing this headrest, a method of forming a foamed molded body and then covering a separately formed skin body was generally used. However, a large number of man-hours are required for coating, and deformation may occur during coating. In recent years, a method in which a bag-like skin is placed in a mold and integrally foam-molded is becoming mainstream.
[0003]
In the case of an armrest or the like, since there is no appropriate place for providing an injection port due to a problem in design, a manufacturing method of performing cover sewing after forming a foamed molded body and a skin body is performed.
[0004]
In this manufacturing method for integral foam molding of a skin, a bag-shaped skin body previously formed by sewing or the like is first placed in a mold. At this time, a reinforcing core material is generally placed inside the epidermis. Then, a foamed resin is injected into the epidermis, and the injection port is closed to perform foam molding. The foamed resin is foamed to increase its volume, and the epidermis is filled in a state of being shaped by pressing the epidermis against the mold surface with the pressure. Therefore, it can be said that it is an excellent manufacturing method because man-hours are small and high shape accuracy is obtained.
[0005]
Incidentally, when the headrest shown in FIGS. 3 and 4 is manufactured by the above manufacturing method, for example, as shown in Japanese Patent Laid-Open No. 4-279307, an opening 100 for injecting a foamed resin is required in the skin. is there. This opening 100 is also used as an insertion port for the core material, and is generally provided at the center of the lower surface of the headrest. As a product, the opening 100 needs to be closed from the viewpoint of design.
[0006]
As a method of closing the opening, as shown in FIG. 4, the opening 100 is provided with a pair of folded portions 101 and 102 which are bent inward and face each other and come into contact with each other. If it does in this way, the folding | returning part 101,102 will be pressed so that it may mutually adjoin by foaming pressure, and it can close the opening 100, preventing the resin leak from the opening 100. FIG. Note that the lengths of the folded portions 101 and 102 need to be sufficiently long so that the foamed resin can be prevented from entering between the pair of folded portions 101 and 102.
[0007]
[Problems to be solved by the invention]
In the conventional manufacturing method, the opening 100 is provided at the center of the lower surface of the headrest. However, such a manufacturing method has a problem that the number of cutting pieces constituting the skin before sewing is large and the number of sewing steps is large.
[0008]
Therefore, it can be considered that the existing sewing portion 200 of the headrest shown in FIG. 3 is also used as an opening and an injection port. If it does in this way, an armrest etc. can also be formed by skin integral foam molding, and a man-hour can be reduced greatly.
[0009]
Also in this case, the folded portion of the injection port is necessary, and a sufficiently long folded portion is necessary. However, in the sewing part 200, the skin (cut pieces) on both sides of the sewing part 200 is bent at the sewing part 200. Accordingly, at least one folded portion is close to one skin.
[0010]
Therefore, when foam molding is performed using such a folded portion, the end of one folded portion 101 is fixed in contact with the skin 103 as shown in FIG. There was a problem that the filling of the foamed resin was hindered and the appearance and feel were impaired.
[0011]
This invention is made | formed in view of such a situation, and it aims at utilizing the existing sewing part as an opening and an injection hole, and preventing an external appearance defect and a tactile sensation defect.
[0012]
[Means for Solving the Problems]
The method for producing a foam integrated with a skin according to the present invention includes a first skin and a second skin that are folded back by a sewing portion that is sewn in accordance with a middle surface, and an opening made of a non-sewn portion at a part of the sewing portion. Is formed and has a first folded portion in which the first skin that is opposed in the opening is folded back and a second folded portion in which the second skin is folded, and the first folded portion is folded so as to face the first skin. Placing the bag-shaped skin in the mold,
Inserting an injection nozzle into the opening and injecting a predetermined amount of foamed resin into the epidermis from the injection nozzle;
By pressing with a pressing plate attached to the mold, the foamed resin is foamed and foamed while maintaining the state where the first folded portion is pressed against the first skin, and the first folded portion is pressed against the first skin. And a step of fixing the performed state.
[0013]
[Action]
The skin used in the production method of the present invention has a bag shape in which a plurality of skins (cut pieces) are sewn. The plurality of skins are reversed after being sewn in accordance with the middle surface, and the sewing end portions protrude into the bag-like interior. An opening made of a non-sewn portion is formed in a part of the sewing portion, and the opening functions as an insertion port for a core material or an injection port for foamed resin.
[0014]
Inside the opening formed of the non-sewn portion, the first folded portion where the first skin is folded is opposed to the second folded portion where the second skin is folded. The first skin and the second skin make an angle, and the first folded portion is folded so as to face the first skin, and the angle formed by the first folded portion and the first skin is an acute angle.
[0015]
And when it has a core material, a core material is inserted in an inside of an outer skin body from opening, and an outer skin body is arrange | positioned in a shaping | molding die. Next, an injection nozzle is inserted into the opening, and a predetermined amount of foamed resin is injected from the injection nozzle into the epidermis.
[0016]
Then, the injection nozzle is removed from the opening, and the foamed resin is foamed while maintaining the state where the first folded portion is pressed against the first skin. This can be done by pressing the pressing plate with a movable type or the like.
[0017]
By foaming the foamed resin in this way, the first folded portion is fixed in a state of being pressed against the first skin. Therefore, it is prevented that a space exists between the first folded portion and the first skin, and appearance and tactile sensations due to poor filling are prevented. Further, by sufficiently increasing the lengths of the first folded portion and the second folded portion, it is possible to prevent the foamed resin from leaking between the first folded portion and the second folded portion.
[0018]
【Example】
Hereinafter, the present invention will be described in detail with reference to FIG. 1 and FIG. In this embodiment, the present invention is applied to manufacture of a headrest of an automobile.
[0019]
Although not shown, the skin 1 is composed of a urethane film layer and a slab foam layer integrally bonded to the back surface of the film layer. The epidermis 1 is composed of a plurality of cut epidermis including a first epidermis 10 and a second epidermis 11, and is formed into a bag shape by sewing.
[0020]
An opening 12 made of a non-sewn part is formed in a part of the sewn part where the first skin 10 and the second skin 11 are joined. The opening 12 is formed between a first folded portion 13 where the first skin 10 is folded inward and a second folded portion 14 where the second skin 11 is folded inward, and the first folded portion 13 and the second folded portion 14 are formed. Each length of the folding | returning part 14 is 50-70 mm.
[0021]
A core material (not shown) is inserted into the skin 1 from the opening 12, and the whole is disposed in the molding die 2.
[0022]
The mold 2 includes a pair of fixed molds 20 and 21 and a movable mold 22. One end of the pressing plate 3 having a thickness of 1 mm is fixed to the upper end surface of the fixed mold 20, and the other end of the pressing plate 3 is swingable. The tip of the other end is configured to protrude about 15 mm into the cavity when rocked at a substantially right angle with respect to the one end.
[0023]
The movable mold 22 is in sliding contact with the fixed mold 21 and clamps the pressing plate 3 together with the fixed mold 20 when driven forward in a direction close to the fixed mold 20.
[0024]
When the movable mold 22 is in the retracted position, the injection nozzle 4 is inserted into the skin body 1 arranged in the mold 2 from the opening 12 as shown in FIG. Then, the other end portion of the pressing plate 3 is pressed by the lowering of the injection nozzle 4, and the first folding portion 13 is pressed in the direction close to the first skin 10 by the swinging of the pressing plate 3. The injection nozzle 4 is inserted until the tips are positioned below the tips of the first folded portion 13 and the second folded portion 14, and foam resin is prevented from adhering to the vicinity of the opening 12.
[0025]
When a predetermined amount of foamed resin 5 is injected from the injection nozzle 4 into the epidermis 1, the injection nozzle 4 rises and is removed from the opening 12, and the movable mold 22 advances to move the pressing plate 3 to the fixed mold 20. Press and hold (FIG. 2). In this state, the first folded portion 13 is pressed against the first skin 10, and no space is generated between the first folded portion 13 and the first skin 10.
[0026]
When the foamed resin 5 is foamed and fills the inside of the skin 1, the second folded portion 14 is pressed against the pressing plate 3 by the foaming pressure, and the opening 12 is closed. This prevents the foamed resin from leaking from the opening 12.
[0027]
Thereafter, the mold 2 is opened and the pressing plate 3 is removed from the opening 12, so that the first folded portion 13 and the second folded portion 14 are in elastic contact with each other by their own elastic force, and the presence of the opening 12 is apparent from the appearance. Disappear.
[0028]
【The invention's effect】
That is, according to the manufacturing method of the skin integrated foam product of the present invention, since the opening for core material insertion and pouring is provided in the sewing portion of the skin body, the appearance quality is improved and the number of sewing steps is reduced by reducing the number of cutting pieces. Can be reduced.
[0029]
And since it can prevent reliably that an unfilled part generate | occur | produces between a folding | turning part and an outer skin at the time of foam molding, generation | occurrence | production of the defective article on an external appearance and a tactile sensation can be prevented.
[0030]
In addition, since an opening is provided in the existing sewing portion, armrests and the like that have conventionally been difficult to integrally form without being provided with an opening can be manufactured by integral foam molding of the skin, and the man-hour can be greatly reduced. .
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a mold and an outer skin immediately before foam molding in an embodiment of the present invention.
FIG. 2 is a cross-sectional view of a mold after foam molding and a foam integrated with a skin in one embodiment of the present invention.
FIG. 3 is a perspective view of a headrest manufactured by a conventional manufacturing method.
FIG. 4 is a cross-sectional view of a main part of a headrest manufactured by a conventional manufacturing method.
FIG. 5 is an explanatory cross-sectional view showing a defective portion of a skin-integrated foamed product produced by a conventional manufacturing method.
[Explanation of symbols]
1: skin body 2: molding die 3: pressing plate 4: injection nozzle 5: foamed resin 10: first skin 11: second skin 12: opening 13: first folding portion 14: second folding portion

Claims (3)

The first and second skins are folded back by a sewing part that is sewn in accordance with the middle surface, and an opening made of a non-sewn part is formed in a part of the sewing part, and the first and second skins facing each other in the opening. A bag-like skin body having a first folded portion in which one skin is folded and a second folded portion in which the second skin is folded, and the first folded portion is folded so as to face the first skin. Placing in a mold; and
Inserting an injection nozzle into the opening and injecting a predetermined amount of foamed resin into the epidermis from the injection nozzle;
By pressing with a pressing plate attached to the mold, the foamed resin is foamed and foam-molded while the first folded portion is kept in pressure contact with the first skin, and the first folded portion is And a step of fixing the state pressed against the first skin, and a method for producing a skin integrated foam. The manufacturing method of the skin-integrated foamed product according to claim 1, wherein one end of the pressing plate is fixed to the mold and the other end is swingable. The manufacturing method of the skin integrated foam product according to claim 1, wherein the pressing plate is pressed by a movable mold.

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