JP3681722B2 - Cushion body manufacturing method and apparatus - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a cushion body manufacturing method and a manufacturing apparatus thereof. In the cushion body according to the present invention, a long suspension groove for fixing a skin cover to be attached later is provided on the surface. The present invention relates to a manufacturing method and an apparatus for manufacturing the same when the hanging groove is wider than the surface. The cushion body according to the present invention is used for a seat back that becomes a backrest portion when a person sitting on a vehicle, such as an automobile, a train, an aircraft, or a ship or for furniture, and a seat cushion that becomes a seating portion when a person sits. It is preferable.
[0002]
[Prior art]
A cushion body for a vehicle or furniture is generally formed of a polyurethane foam (see, for example, Patent Document 1). The cushion body is assembled after being covered with a skin cover such as cloth or leather, and becomes a seat back, a seat cushion or the like as a finished product. For example, in the case of a vehicle seat back or the like, the obtained seat backs and the like are assembled together, and other members such as an armrest are also assembled into a seat and assembled to the vehicle.
[0003]
Therefore, a suspension groove having a predetermined width for fixing the skin cover is recessed from the surface of the cushion body. An elongated fixing member having rigidity such as a metal wire is integrally embedded along the suspension groove inside the bottom of the suspension groove. On the other hand, a suspension member made of a long and thin bag is sewn on the back surface side of the skin cover, and a long and fixed member such as a metal wire is inserted into the suspension member. When assembling the skin cover to the cushion body, the suspension member and the fixed member of the skin cover are positioned in the suspension groove of the cushion body, and the fixing member and the fixed member in the suspension groove are fixed by a fixture called a C ring. Fixing is done. This fixing tool or this fixing work may be referred to as “hoggling” in the art.
[0004]
In order to manufacture such a cushion body, the following manufacturing apparatus is used. The manufacturing apparatus includes a foam mold having a first mold that forms the front surface side of the cushion body and a second mold that can be opened and closed with respect to the first mold and that forms the back surface side of the cushion body. . In general, the first mold is a lower mold as a fixed mold fixed to a base, and the second mold is an upper mold as a movable mold that can be opened and closed so as to rotate with respect to the lower mold via a hinge. is there. On the molding surface of the lower mold of the foam molding die, a ridge that can form a hanging groove is projected toward the upper die, and the shape corresponding to the cushion body when the upper die and the lower die are closed. A cavity is formed.
[0005]
And when manufacturing a cushion body with this manufacturing apparatus, as a 1st process, when a lower mold | type and an upper mold | type are open, a fixing member is fixed along a protruding item | line. Thereafter, after the foamable raw material is injected into the cavity as the second step, the lower mold and the upper die are closed and the foamable raw material is foamed and filled into the cavity as the third step. Thereby, while forming a hanging groove | channel with a protruding item | line, the cushion body which embed | buried the fixing member integrally is formed. Thereafter, as a fourth step, the lower mold and the upper mold are opened, and the cushion body is removed from the lower mold. The cushion body obtained in this way is used as a seat back together with the skin cover, and used as a seat or a sofa for a vehicle or furniture.
[Patent Document 1]
Japanese Patent Laid-Open No. 2002-200266
[0006]
[Problems to be solved by the invention]
However, recently, in such a cushion body, in order to improve aesthetics, it is desired to make the width of the hanging groove as narrow as possible. However, the narrower the width of the suspension groove, the more difficult the hogging operation becomes.
[0007]
As a solution for this, it is conceivable to reduce the width of the surface of the suspension groove of the cushion body and to form a suspension groove that becomes wider toward the back. Thereby, improvement in aesthetics and maintenance of workability of hoggling can be achieved at the same time.
[0008]
However, when manufacturing such a cushion body, it is necessary that the protrusions of the lower mold in the foaming mold correspond to the suspending grooves and have a tip wider than the root. For this reason, when the cushion body is removed from the mold, it is expected that the ridges will be caught undercut at the bottom of the suspension groove, and cracks and breaks along the longitudinal direction will occur at the bottom of the suspension groove.
[0009]
The present invention has been made in view of the above-described problem, and even when a cushion body having a hanging groove whose depth is wider than the surface is manufactured, the cushion body can be manufactured without causing cracks or breakage. It is an object to provide a method for manufacturing a cushion body and a manufacturing apparatus therefor.
[0010]
[Means for Solving the Problems]
In order to solve the above problems, the inventors have observed in detail the operation of the lower mold and the foam in the case of manufacturing a cushion body having a hanging groove that is wider from the surface. In that case, the inventors try to move the foam with the movement of the upper mold when the upper mold is opened, but a part of the side wall of the suspension groove portion of the foam is formed by a protrusion having a wider tip than the root. It has been found that the undercut has occurred and the portion is held by the ridges. In addition, when the upper mold is further opened in this state, the inventors are in a state in which the foam is bent with the hanging groove portion as a break point (bending center), and then the cushion body is removed from the convex stripes. I found out. And from these findings, the inventors have found that the cause of cracks and breakage is the width direction of the suspension groove at the bottom of the suspension groove when the suspension groove opens widely at such a break point (bent center). It was discovered that a large pulling force was generated and distortion (deformation) exceeding the limit occurred, and the present invention was completed.
[0011]
That is, the cushion body manufacturing method according to the first aspect of the present invention is a foam cushion body in which a long suspension groove is recessed on the surface, and a rigid elongated fixing member is integrally embedded along the suspension groove. A manufacturing method of
[0012]
A first mold that forms a front surface side of the cushion body, and a second mold that is openable and closable with respect to the first mold and forms a back surface side of the cushion body, the first mold and the first mold Using a foaming mold in which a cavity having a shape corresponding to the cushion body is formed when the two molds are closed,
[0013]
The suspension groove can be formed on the molding surface of the first mold, and a protrusion having a wider tip than the base is formed protruding toward the second mold.
[0014]
The second mold is formed with holding means that faces the ridge when the first mold and the second mold are closed, and moves in the opening / closing direction together with the second mold,
[0015]
A first step of fixing the fixing member along the ridge when the first mold and the second mold are open;
[0016]
A second step of injecting a foamable raw material into the cavity;
[0017]
The first mold and the second mold are closed, the foamable raw material is foamed and filled into the cavity, and the hanging groove having a width wider than the surface is formed by the protrusions, and the fixing member A third step of forming the cushion body integrally embedded with
[0018]
When the first mold and the second mold are opened and the cushion body is removed from the first mold, the holding means moves along with the movement of the second mold in the opening direction, and the ridges are moved. And a fourth step of applying a force in a direction away from the ridge to the surrounding foam.
[0019]
The cushion body may integrally have a cloth-like auxiliary material having higher bending strength and rigidity than the foam on the back surface, but the manufacturing method of the first invention produces a cushion body that does not necessarily require the auxiliary material. Is for. In this manufacturing method, a hanging groove can be formed on the molding surface of the first mold of the foam molding die, and a protrusion having a wider tip than the base is formed protruding toward the second mold. Further, the second mold of the foam mold is formed with holding means that faces the ridges when the first mold and the second mold are closed and moves in the opening / closing direction together with the second mold. Then, in the third step, a hanging groove having a width wider than the surface is formed by the ridges. Further, in the fourth step, the holding means moves with the movement of the second mold in the opening direction, and exerts a force in a direction away from the ridges on the foam around the ridges. For this reason, according to this manufacturing method, an excessive tearing force does not occur in the foam around the ridge when the mold is opened.
[0020]
Therefore, according to this manufacturing method, when manufacturing the cushion body which has a hanging groove whose back | inner side is wider than the surface, the cushion body can be manufactured, without producing a crack and damage.
[0021]
Although it does not specifically limit as a foamable raw material, The raw material which mixed the suitable foaming agent, the catalyst, etc. with the mixing raw material of the polyol raw material and isocyanate raw material which form a polyurethane foam is preferable. A raw material obtained by mixing carbon dioxide or the like as a foaming agent with such a mixed raw material is also applicable.
[0022]
In the manufacturing method of the first invention, the holding means is formed so as to protrude into the cavity, and is capable of holding the fixing member by contacting the fixing member when the first mold and the second mold are closed. obtain. Then, in the fourth step, the holding means moves while holding the fixing member as the second mold moves in the opening direction, and forces the foam around the ridge away from the ridge through the fixing member. Work. In this case, in the fourth step, the force for opening the second mold directly acts on the fixing member via the holding member, and this force is transmitted to the entire length of the elongated fixing member, so that it is wide in the longitudinal direction of the suspension groove. Thus, the cushion body can be removed from the first mold by preventing the foam from cracking or breaking. Thus, even with this manufacturing method, excessive tearing force does not occur in the foam around the ridges when the mold is opened.
[0023]
In the manufacturing method of the first invention, when the fixing member is a steel wire, the holding means may be a magnet. Then, in the fourth step, the magnet moves by magnetizing the steel wire as the second mold moves in the opening direction, and forces the foam around the ridge away from the ridge through the steel wire. Can work. In this case, in the fourth step, the opening force of the second mold acts on the fixing member via the magnet, and this force is transmitted to the entire length of the elongated fixing member, so that foaming occurs in a wide range along the longitudinal direction of the suspension groove. The cushion body can be removed from the first mold by preventing the body from cracking or breaking. Further, in the third step, it is possible to prevent the fixing member from being displaced in the molding surface direction during the foaming flow of the foamable raw material. As a magnet, an electromagnet can be adopted in addition to a permanent magnet.
[0024]
In the manufacturing method of the first invention, the holding means may be capable of holding the fixing member by mechanically locking the fixing member. As such a holding means, when the fixing member is a steel wire, a hook can be adopted. Then, in the fourth step, the holding means mechanically locks and moves the fixing member along with the movement of the second mold in the opening direction, and the foam around the ridge moves from the ridge to the foam around the fixing member. You can apply force in the direction of leaving. In this case, in the fourth step, the opening force of the second mold acts stably on the fixing member via the holding means, and this force is transmitted and acts on the entire length of the elongated fixing member. The cushion body can be removed from the first mold by preventing the foam from cracking or breaking in a wide range.
[0025]
In the manufacturing method of the first invention, the cushion body may integrally have a cloth-like auxiliary material having higher bending strength and rigidity than the foam on the back surface. As the auxiliary material, a nonwoven fabric, a woven fabric, paper, a flexible plastic sheet, or the like can be used.
[0026]
In the manufacturing method of the first invention, when the cushion body integrally has a cloth-like auxiliary material having higher bending strength and rigidity than the foam, the holding means is a holding member protruding into the cavity. obtain. In the first step, the holding member is locked in the holding hole formed in the auxiliary material. In the third step, the auxiliary material is integrated with the foam. In the fourth step, the holding member holds the auxiliary material as the second mold moves in the opening direction. The It moves as it is, and a force is applied to the foam around the ridge through the auxiliary material in the direction away from the ridge. In this case, since the auxiliary material has higher bending strength and rigidity than the foam constituting the cushion body, the force acting on the auxiliary material is not limited to the position of the holding member but also extends to the vicinity thereof. For this reason, it is possible to more stably prevent cracks and breakage of the foam around the ridges and remove the cushion body from the first mold. In this case, since the position where the force is applied can be determined simply by passing the holding member through the auxiliary material, excellent workability can be exhibited.
[0027]
In the manufacturing method of the first invention, when the cushion body integrally has a cloth-like auxiliary material having higher bending strength and rigidity than the foam on the back surface, the holding means is attached to the molding surface of the second mold. It can be a face fastener. In the first step, one surface of the auxiliary material is locked to the surface fastener. In the third step, the other surface of the auxiliary material is integrated with the foam. In the fourth step, the hook-and-loop fastener holds the auxiliary material as the second mold moves in the opening direction. The It moves as it is, and a force is applied to the foam around the ridge through the auxiliary material in the direction away from the ridge. In this case, the auxiliary material is preferably a non-woven fabric that can be easily locked to the hook-and-loop fastener. Thus, since the auxiliary material has higher bending strength and rigidity than the foam constituting the cushion body, a stable force can be applied in a wide range continuous along the longitudinal direction of the suspension groove. For this reason, it is possible to more reliably prevent the foam from being cracked or broken around the ridge, and to remove the cushion body from the first mold. In this case, it is not necessary to form a hole in the auxiliary material, and excellent workability is exhibited.
[0028]
In the manufacturing method of the first invention, the holding means is provided at a plurality of positions along the suspension groove at intervals, and in the fourth step, the holding means moves in the longitudinal direction of the suspension groove as the second mold moves in the opening direction. It is preferable to apply a force to the foam around the ridge in a direction away from the ridge at a plurality of positions along the ridge. In this case, since a force can be applied around the ridge at a plurality of locations in the longitudinal direction of the suspension groove, a stable force can be applied along the longitudinal direction of the ridge.
[0029]
According to a second aspect of the present invention, there is provided a cushioning body manufacturing apparatus for manufacturing a foamed cushioning body in which a long suspension groove is recessed on a surface, and a rigid elongated fixing member is integrally embedded along the suspension groove. A device,
[0030]
A first mold that forms a front surface side of the cushion body, and a second mold that is openable and closable with respect to the first mold and forms a back surface side of the cushion body, the first mold and the first mold A foam molding die in which a cavity having a shape corresponding to the cushion body is formed when the two molds are closed;
[0031]
The suspension groove can be formed on the molding surface of the first mold, and a protrusion having a wider tip than the base is formed protruding toward the second mold.
[0032]
The second mold is formed with a holding means that is located at or near the portion facing the ridge when the first mold and the second mold are closed, and moves in the opening / closing direction together with the second mold. And
[0033]
When the first mold and the second mold are open, the fixing member is fixed along the ridges, a foamable raw material is injected into the cavity, and the first mold and the second mold are Closes, foams the foamable raw material and fills the cavity, and the ridges form the hanging grooves wider than the surface and form the cushion body in which the fixing member is embedded integrally. When the first mold and the second mold are opened and the cushion body is removed from the first mold, the holding means moves and moves in the opening direction of the second mold. The foam around the ridge is configured to be able to exert a force in a direction away from the ridge.
[0034]
The manufacturing apparatus of the second invention is for manufacturing a cushion body that does not necessarily require a supplement. This manufacturing apparatus has substantially the same effect as the manufacturing method of the first invention.
[0035]
Therefore, also with this manufacturing apparatus, when manufacturing a cushion body having a hanging groove wider than the surface, the cushion body can be manufactured without causing cracks or breakage.
[0036]
In the manufacturing apparatus of the second invention, the holding means is formed so as to protrude into the cavity, and is capable of holding the fixing member by contacting the fixing member when the first mold and the second mold are closed. obtain. As the second mold moves in the opening direction, the holding means moves while holding the fixing member, and a force can be applied to the foam around the ridge in a direction away from the ridge through the fixing member. Can be configured. In this case, the opening force of the second mold directly acts on the fixing member via the holding member, and this force is transmitted to the entire length of the elongated fixing member, so that the foam cracks in a wide range along the longitudinal direction of the suspension groove. The cushion body can be removed from the first mold while preventing damage. Thus, even with this manufacturing apparatus, excessive tearing force does not occur in the foam around the ridges when the mold is opened.
[0037]
Also in the manufacturing apparatus of the second invention, when the fixing member is made of a magnetic material, the holding means may be a magnet capable of magnetizing the fixing member. As the second mold moves in the opening direction, the magnet moves while adhering to the fixing member, and a force can be exerted on the foam around the ridge in a direction away from the ridge through the fixing member. Can be configured. In this case, in the fourth step, the opening force of the second mold acts on the fixing member via the magnet, and this force is transmitted to the entire length of the elongated fixing member, so that foaming occurs in a wide range along the longitudinal direction of the suspension groove. The cushion body can be removed from the first mold by preventing the body from cracking or breaking. Further, in the third step, it is possible to prevent the fixing member from being displaced in the molding surface direction during the foaming flow of the foamable raw material. As a magnet, an electromagnet can be adopted in addition to a permanent magnet.
[0038]
Also in the manufacturing apparatus of the second invention, the holding means may be capable of holding the fixing member by mechanically locking the fixing member. As such a holding means, when the fixing member is a steel wire, a hook can be adopted. Then, as the second mold moves in the opening direction, the holding means mechanically locks and moves the fixing member, and forces the foam around the ridge to move away from the ridge through the fixing member. Can be configured to work. In this case, in the fourth step, the opening force of the second mold acts stably on the fixing member via the holding means, and this force is transmitted and acts on the entire length of the elongated fixing member. The cushion body can be removed from the first mold by preventing the foam from cracking or breaking in a wide range.
[0039]
In the manufacturing apparatus of the second invention, the cushion body may integrally have a cloth-like auxiliary material having higher bending strength and rigidity than the foam on the back surface. As the auxiliary material, a nonwoven fabric, paper, a flexible plastic sheet, or the like can be employed.
[0040]
In the manufacturing apparatus of the second invention, when the cushion body integrally has a cloth-like auxiliary material having higher bending strength and rigidity than the foam on the back surface, the holding means is a holding member protruding into the cavity. obtain. Then, the holding member is locked in the holding hole formed in the auxiliary material, the auxiliary material is integrated with the foam, and the holding member holds the auxiliary material as the second mold moves in the opening direction. The It can be configured to be able to move as it is and to apply a force to the foam around the ridge in a direction away from the ridge through the auxiliary material. In this case, since the auxiliary material has higher bending strength and rigidity than the foam constituting the cushion body, the force acting on the auxiliary material is not limited to the position of the holding member but also extends to the vicinity thereof. For this reason, it is possible to more stably prevent cracks and breakage of the foam around the ridges and remove the cushion body from the first mold. In this case, since the position where the force is applied can be determined simply by passing the holding member through the auxiliary material, excellent workability can be exhibited.
[0041]
It is preferable that the front end of the holding member has a locking portion that locks the auxiliary material when it passes through the auxiliary material. Accordingly, the auxiliary material can be easily mounted so that the holding member passes through the auxiliary material and the tip protrudes from the back surface of the auxiliary material.
[0042]
The front end of the locking portion can be bent in the direction of taking out the cushion body. In this case, in the fourth step, the locking portion pulls up the auxiliary material and the surrounding cushion body, so that the cushion body can be moved more stably. Moreover, since the latching | locking part has faced the taking-out direction of a cushion body, there are few catches at the time of taking out after a 4th process, and it is easy to take out without producing a crack and damage.
[0043]
In the manufacturing apparatus of the second invention, when the cushion body integrally has a cloth-like auxiliary material having higher bending strength and rigidity than the foam on the back surface, the holding means is attached to the molding surface of the second mold. It can be a face fastener. Then, one surface of the auxiliary material is locked to the surface fastener, the other surface of the auxiliary material is integrated with the foam, and the surface fastener holds the auxiliary material as the second mold moves in the opening direction. The It can be configured to be able to move as it is and to apply a force to the foam around the ridge in a direction away from the ridge through the auxiliary material. In this case, since the auxiliary material has higher bending strength and rigidity than the foam constituting the cushion body, a stable force can be applied in a wide range continuous along the longitudinal direction of the suspension groove. For this reason, it is possible to more reliably prevent the foam from being cracked or broken around the ridge, and to remove the cushion body from the first mold. In this case, it is not necessary to form a hole in the auxiliary material, and excellent workability is exhibited.
[0044]
In the manufacturing apparatus according to the second aspect of the invention, the holding means is provided at a plurality of locations along the suspension groove at intervals, and the holding means is provided at a plurality of locations along the longitudinal direction of the suspension groove as the second mold moves in the opening direction. It is possible to apply a force to the foam around the ridge in a direction away from the ridge at the position of. In this case, since a force can be applied around the ridge at a plurality of locations in the longitudinal direction of the suspension groove, a stable force can be applied along the longitudinal direction of the ridge.
[0045]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, Embodiments 1 to 5 embodying the present invention will be described with reference to the drawings.
[0046]
(Embodiment 1)
In the first embodiment, as shown in FIG. 1, a method and an apparatus for manufacturing a foam cushion body 1 that serves as a seat back of an automobile seat will be described. FIG. 1 is an overall perspective view of the cushion body 1 as seen from the surface side. FIG. 2 is a cross-sectional view taken along line II-II in FIG. FIG. 3 is a partially enlarged view of the hanging groove portion.
[0047]
As shown in FIG. 2, the cushion body 1 is formed in a folded shape so as to have a lower end portion 1 b that is bent toward the back side on the lower side of the cushion body 1 a and a space inside on the upper side. The slipper portion 1c is integrally provided. A long suspension groove 2 is recessed in the surface of the main body 1a. The cushion body 1 integrally has a cloth-like auxiliary material 3 on the back surface. As shown in FIG. 3, the suspension groove 2 is wider at the back than the surface. A steel wire 4 as a rigid and elongated fixing member is integrally embedded along the longitudinal direction of the suspension groove 2 at the bottom of the suspension groove 2. The auxiliary material 3 is a nonwoven fabric in which a large number of fibers are entangled, and has higher bending strength and rigidity than a foam. This cushion body 1 is assembled to the vehicle body after a skin cover 5 such as cloth or leather is covered in a subsequent process, and becomes a cushion body 1 as a finished product. A suspension member 5a made of a long and thin bag is sewn on the back side of the skin cover 5, and a steel wire 5b as a fixed member is inserted into the suspension member 5a. When hogging, the suspension member 5a and the steel wire 5b of the skin cover 5 are positioned in the suspension groove 2 of the cushion body 1, and the steel wire 4 and the steel wire 5b are connected to each other by a C-ring 6 as a fixture in the suspension groove 2. Fix it. In FIG. 1, reference numeral 7 is a hole for inserting a headrest column, and reference numeral 1 d is a side portion of the cushion body 1.
[0048]
In order to manufacture the cushion body 1, a manufacturing apparatus including the foaming mold 10 shown in FIGS. 4 and 5 is prepared. The foaming mold 10 includes a lower mold 11 that forms the surface side of the cushion body 1, and an upper mold 12 that can be opened and closed with respect to the lower mold 11 around the hinge center O and that forms the back surface side of the cushion body 1. . The lower mold 11 is a fixed mold fixed to a base (not shown), and the upper mold 12 is a movable mold that can be opened and closed so as to rotate in the same direction together with the upper mold body 13. On the lower mold 11, protruding ridges 11 a capable of forming the suspension grooves 2 are formed protruding toward the upper mold 12. The upper mold 12 has an arm 12a that protrudes upward on the surface side, and a slipper that is a part of the main body 13 is formed at the tip of the upper mold 12 when the upper mold main body 13 moves in the opening direction. It has a substantially square hooking part 12b that is hooked on the part 13a and moves the upper mold 12 in the opening direction. Further, the upper mold 12 is formed with a protruding portion 12c for forming a back space of the slipper portion 1c of the upper mold 12 of the cushion body 1. As will be described later, the protrusion 12c holds the cushion body 1 and moves it in the moving direction of the upper mold 12 when the cushion body 1 is removed from the mold.
[0049]
Each ridge 11a has a wider tip than the base, and the tip is rounded in the width direction. A first permanent magnet 11b is embedded at the tip of each protrusion 11a. A plurality of holding members 21 which are holding means for holding the auxiliary material 3 are screwed to the upper mold 12. More specifically, as shown in FIGS. 6 and 7, holding members 21 are screwed at a plurality of locations with a gap in the direction along the ridge 11 a. Each holding member 21 protrudes from the molding surface of the upper die 12 toward the molding surface of the lower die 11 when the die is closed, and has a diameter larger than the base on the tip side beyond the thickness of the auxiliary material 3 of each holding member 21. The locking portion 21a is formed. A similar holding member 22 is provided at a portion near the hinge center O of the upper mold 12 for fixing the auxiliary material 3. As a method for fixing the holding members 21 and 22 to the foaming mold 10, welding, adhesion, or a combination thereof may be considered in addition to screwing. In addition, the holding members 21 and 22 can be formed integrally with the foam molding die 10. As shown in FIG. 5, when the lower mold 11 and the upper mold 12 are closed, the molding surfaces of the lower mold 11, the upper mold 12, and the upper mold main body 13 are substantially sealed in a shape corresponding to the cushion body 1. A cavity C is formed. 4 and 5, arrows P1 and P2 indicate the opening directions of the upper mold body 13 and the upper mold 12, respectively. Further, as is apparent from the drawings, when the mold is opened, the upper mold body 13 first moves in the opening direction indicated by the arrow P1, and the slipper forming portion 13a of the upper mold body 13 contacts the catching section 12b of the upper mold 12. Thereafter, the upper mold 12 is moved in the opening direction of the arrow P2, and the mold opening is performed.
[0050]
When the cushion body 1 is manufactured by this manufacturing apparatus, first, as shown in FIG. 4, when the lower mold 11 and the upper mold 12 are opened, the steel wire 4 that is a fixing member is a first process. The permanent magnet 11b is fixed along the ridge 11a by magnetic attachment. Further, the auxiliary members 3 are arranged along the molding surface of the upper die 12 so that the respective holding members 21 pass through the holding holes 3 a (see FIG. 3) formed in the auxiliary material 3 in advance and the tips protrude from the back surface of the auxiliary material 3. Mounting. At this time, the auxiliary material 3 attached by the locking portion 21a is prevented from falling off the upper mold 12.
[0051]
And as a 2nd process, well-known foaming raw materials, such as a mixed material of a liquid polyol and the same isocyanate, are inject | poured into the cavity C. FIG. Thereafter, as a third step, as shown in FIG. 5, the upper mold 12 is moved toward the lower mold 11 to close the mold, the foamable raw material is foamed, and the volume expansion accompanying the foaming causes the cavity C to enter the cavity C. Filled to form a flexible and elastic polyurethane foam. In this process, the suspension groove 2 is formed by the ridge 11a, the holding member 21 including the locking portion 21a is wrapped from the outside, the steel wire 4 is embedded integrally, and the auxiliary material 3 is integrally bonded. The cushion body 1 is formed. The polyurethane foam is joined to the auxiliary material 3 by welding, enters the gap between the fibers of the auxiliary material 3 and is firmly fixed by the anchor effect, and further, the polyurethane foam bubbles are crushed at the joined portion to form polyurethane. The resin content (non-foamed content) is larger than that of the internal polyurethane foam to increase the density, and accordingly, the rigidity is higher than the internal content. Thereby, on the back surface side, the rigidity is higher than the rigidity of the auxiliary material 3 alone due to a synergistic effect with the rigidity of the auxiliary material 3.
[0052]
Thereafter, as a fourth step, the upper mold 12 is opened with respect to the lower mold 11 as shown in FIG. That is, first, the upper mold body 13 moves in the opening direction of the arrow P1 so that the slipper forming portion 13a contacts the catching section 12b of the upper mold 12, and then the upper mold body 13 moves further as the upper mold body 13 moves further. Move in the opening direction of arrow P2. At this time, a space S is formed between the slipper forming portion 13a and the protruding portion 12c, and the mold is removed through the space S when the cushion body 1 is removed from the upper mold 12 as described later. When the mold is opened, the holding member 21 moves with the movement of the upper mold 12 in the opening direction, and the holding member 21 moves the cushion body 1 and the auxiliary material 3 in the opening direction by the engaging portion 21a. By moving the cushion body 1 integrated with the auxiliary material 3 through the auxiliary material 3, a force is applied to the foam around the protruding item 11a in a direction away from the protruding item 11a. That is, when the upper mold 12 moves in the opening direction, the protrusion 12 of the upper mold 12 moves in the slipper part 1c arrow P2 direction of the cushion body 1 and acts to peel the cushion body 1 from the lower mold 11, Also in the portion of the ridge 11a, the holding member 21 acts so as to move the same angle as the protrusion 12 with respect to the hinge center O to peel the cushion pair from the lower mold 11. For this reason, when the mold is opened, the cushion body 1 is not bent at the portions of the ridges 11 a and the suspending grooves 2, and no excessive local pulling force is generated in the suspending grooves 2. In particular, since the auxiliary material 3 is more rigid than the foam that constitutes most of the cushion body 1 and is integrated with the foam, the force acting on the auxiliary material 3 is limited to the position of the holding member 21. It extends widely to the foam in the vicinity. For this reason, according to this manufacturing method, an excessive tearing force does not occur in the foam around the ridge 11a when the mold is opened. In addition, since the holding member 21 is provided at a plurality of locations at intervals in the direction along the ridge 11a, force can be applied to the foam around the ridge 11a at a plurality of locations in the longitudinal direction of the suspension groove 2. A stable force can be applied along the longitudinal direction of the ridge 11a. Thus, the cushion body 1 is removed from the lower mold 11.
[0053]
Therefore, according to this manufacturing method, when manufacturing the cushion body 1 which has the suspension groove | channel 2 whose depth is wider than the surface, the cushion body 1 can be manufactured, without producing a crack and damage. Moreover, according to this manufacturing method, since the position of the auxiliary | assistant material 3 can be determined only by letting the holding member 21 pass in a 1st process, the outstanding workability | operativity can be exhibited.
[0054]
And if the upper mold | type 12 is completely opened with respect to the lower mold | type 11, the foaming mold 10 will be in the state shown in FIG. In this state, the lower part of the cushion body 1 is pulled forward (in the direction away from the molding surface of the upper mold 12), the lower part of the cushion body 1 is removed from the upper mold 12, the holding members 21 and 22 are removed, and the cushion body 1 is removed. The slipper part 1c is moved in the direction opposite to the folded part of the folded part, and is removed from the upper mold 12 through the space S. In the cushion body 1 obtained in this way, as shown in FIG. 3, the suspending groove 2 whose depth is wider than the surface is recessed by the ridge 11a. The cushion body 1 is used as a seat back together with a skin cover 5 and a frame (not shown), and is used as a seat in an automobile. Since this sheet has a narrow width on the surface side of the suspension groove 2 of the cushion body 1, there is no sag or drop in the vicinity of the opening, and the appearance of the skin cover is improved. On the other hand, since the width of the suspension groove 2 of the cushion body 1 increases toward the back side, the workability of the hog ring does not deteriorate.
[0055]
(Embodiment 2)
In the manufacturing method of the second embodiment, the foaming mold 10 shown in FIG. 10 is used. A plurality of holding members 23 for holding the auxiliary material 3 are screwed onto the upper mold 12 of the foam mold 10 along the ridges 11a. A locking portion 23a that is bent in the same direction as the direction of taking out the cushion body 1 after the fourth step is formed at the tip of each holding member 21. Since other configurations are the same as those of the first embodiment, the same configurations are denoted by the same reference numerals, and detailed description thereof is omitted.
[0056]
In this case, in the 4th process, since the latching | locking part 23a pulls up the auxiliary material 3 and the cushion body 1 of the periphery, the cushion body 1 can be moved more stably. Moreover, since the latching | locking part 23a has faced the taking-out direction of the cushion body 1, there are few catches at the time of taking out after a 4th process, and it is easy to take out without producing a crack and damage. Other functions and effects are the same as those of the first embodiment.
[0057]
(Embodiment 3)
In the manufacturing method of the third embodiment, the foaming mold 10 shown in FIG. 11 is used. A single tape-shaped or a plurality of hook-and-loop males 24 for holding the auxiliary material 3 along the ridges 11a are fixed to the upper mold 12 of the foam mold 10 by bonding or the like. A commercial product sold under a trade name such as “Velcro” (registered trademark) can be used as the hook and loop fastener. Since other configurations are the same as those of the first embodiment, the same configurations are denoted by the same reference numerals, and detailed description thereof is omitted.
[0058]
In this case, when the auxiliary material 3 is attached to the upper mold 12, a large number of protrusions of the male fastener 24 of the hook and loop fastener enter the gap between the fibers of the auxiliary material 3 and are caught by the fibers, and the auxiliary material 3 is attached. In addition, since the auxiliary material 3 is pressed against the molding surface of the upper mold 12 by the foaming pressure during the foam molding of the cushion body 1, the male fastener 24 of the surface fastener is well engaged with the auxiliary material 3 throughout. For this reason, a stable force can be applied in a wide range continuous along the longitudinal direction of the suspension groove 2. Moreover, it is not necessary to form a hole in the auxiliary material 3 in the first step, and excellent workability is exhibited. Other functions and effects are the same as those of the first embodiment.
[0059]
(Embodiment 4)
In the manufacturing method of the fourth embodiment, the foaming mold 10 shown in FIG. 12 is used. A plurality of holding members 25 for holding the steel wire 4 are screwed onto the upper mold 12 of the foam mold 10 along the ridges 11a. A second permanent magnet 25 a capable of magnetizing the steel wire 4 is embedded at the tip of each holding member 25. The polarities of the second permanent magnet 25a and the first permanent magnet 11b are reversed, and when the holding position of the steel wire 4 is determined based on the lower mold 11, the magnetic force of the second permanent magnet 25a is the first. It is preferable to set the shape to be weaker or smaller than the magnetic force of the permanent magnet 11b. Since other configurations are the same as those of the first embodiment, the same configurations are denoted by the same reference numerals, and detailed description thereof is omitted.
[0060]
In this case, in the fourth step, the opening force of the upper mold 12 acts on the steel wire 4 via the second permanent magnet 25a, and this force is transmitted to the entire length of the elongated steel wire 4 so that the suspension groove 2 The cushion body 1 can be removed from the lower mold 11 by preventing cracks and breakage of the foam in a wide range along the longitudinal direction. Further, in the third step, it is possible to prevent the steel wire 4 from being displaced from a predetermined fixed position during the foaming flow of the foamable raw material. Other functions and effects are the same as those of the first embodiment.
[0061]
(Embodiment 5)
In the manufacturing method of the fifth embodiment, the foaming mold 10 shown in FIG. 13 is used. A plurality of holding members 26 for holding the steel wire 4 are screwed onto the upper mold 12 of the foam mold 10 along the ridges 11a. A hook 26a to which the steel wire 4 can be hooked is provided at the tip of each holding member 26 so as to be elastically deformable. Since other configurations are the same as those of the first embodiment, the same configurations are denoted by the same reference numerals, and detailed description thereof is omitted.
[0062]
In this case, when the upper die 12 is closed to the lower die 11, the hook 26 a comes into contact with the steel wire 4, and once deformed as shown by a broken line, the hook 26 a is locked to the steel wire 4 by a restoring force. In the fourth step, the force that opens the upper mold 12 acts stably on the steel wire 4 via the hook 26a, and this force is transmitted to the entire length of the elongated steel wire 4 so that the length of the suspension groove 2 is increased. The cushion body 1 can be removed from the lower mold 11 by preventing cracking and breakage of the foam in a wide range along the direction. In addition, the lock can be removed from the lower mold 11 without being released during the mold removal. Other functions and effects are the same as those of the first embodiment.
[0063]
(Comparison form)
In the comparative manufacturing method, a foam molding die 10 shown in FIG. 14 is used. Nothing is provided on the upper mold 12 of the foam mold 10 along the ridges 11a.
[0064]
In this case, unlike the manufacturing methods and manufacturing apparatuses of the first to fifth embodiments, when the cushion body 1 is removed, a crack cl along the longitudinal direction of the suspension groove 2 is likely to occur at the bottom of the suspension groove 2. More specifically, when the upper mold 12 moves in the direction of the arrow P2 when the mold is opened, the projecting part 12c moves the slipper part 1c away from the lower mold 11. On the other hand, in the portion of the ridge 11a, since the ridge 11a bites into the cushion body 1, the cushion body 1 is prevented from moving away from the lower mold 11 in this portion. As a result, the cushion body 1 is deformed in a bent shape along the thin ridge 11a, and the distortion in the expanding direction exceeding the limit indicated by the arrow x is formed at the bottom of the formed hanging groove 2. It is estimated that cracks will occur. This proves that the effect of the present invention is remarkable.
[0065]
In the present invention, the foam mold is combined with a core mold that moves in a direction away from the lower mold that is a fixed mold in synchronization with the upper mold that is a movable mold, depending on the shape of the cushion body to be manufactured. Sometimes used. In the present invention, such a core type is included in the category of the second type. Further, as described above, the present invention is not limited to the seat back manufacturing method and manufacturing apparatus of each embodiment.
[Brief description of the drawings]
FIG. 1 is a perspective view of a cushion body according to a first embodiment.
2 relates to the cushion body of the first embodiment and is a cross-sectional view taken along the line II-II in FIG.
FIG. 3 is an enlarged cross-sectional view of a main part of the cushion body according to the first embodiment.
FIG. 4 is a cross-sectional view of the foaming mold in the mold open state according to the first embodiment.
FIG. 5 is a cross-sectional view of the foaming mold in the mold closed state according to the first embodiment.
6 is an enlarged cross-sectional view of a main part of a foam mold or the like in a mold closed state according to the first embodiment. FIG.
7 is an enlarged cross-sectional view of a main part in a direction perpendicular to FIG. 6, such as a foam-molding mold in a mold-closed state, according to the first embodiment. FIG.
FIG. 8 is an enlarged cross-sectional view of a main part of a foaming mold or the like in the middle of mold opening according to the first embodiment.
FIG. 9 is a cross-sectional view of the foaming mold and the like after the mold opening according to the first embodiment.
FIG. 10 is an enlarged cross-sectional view of a main part of a foam mold or the like in a mold closed state according to the second embodiment.
FIG. 11 is an enlarged cross-sectional view of a main part of a foam mold or the like in a mold closed state according to the third embodiment.
FIG. 12 is an enlarged cross-sectional view of a main part of a foam mold or the like in a mold closed state according to the fourth embodiment.
FIG. 13 is an enlarged cross-sectional view of a main part of a foam mold or the like in a mold closed state according to the fifth embodiment.
FIG. 14 is an enlarged cross-sectional view of a main part of a foaming mold or the like in the middle of mold opening according to a comparative embodiment.
[Explanation of symbols]
4 ... Fixing member (steel wire)
2 ... hanging groove
1 ... Cushion body
11 ... 1st type (lower type)
12 ... Second type (upper type)
11a ... ridge
C ... Cavity
10 ... Foam mold
21, 23, 24, 25, 26, 3 ... holding means (21, 23, 25, 26 ... holding member, 24 ... hook-and-loop fastener, 3 ... auxiliary material)
21a, 23a ... Locking portion
25a ... second permanent magnet
26a ... hook

Claims (16)

A method for producing a foam cushion body in which a long suspension groove is recessed on the surface and a rigid elongated fixing member is integrally embedded along the suspension groove.
A first mold that forms a front surface side of the cushion body, and a second mold that is openable and closable with respect to the first mold and forms a back surface side of the cushion body, the first mold and the first mold Using a foaming mold in which a cavity having a shape corresponding to the cushion body is formed when the two molds are closed,
The suspension groove can be formed on the molding surface of the first mold, and a protrusion having a wider tip than the base is formed protruding toward the second mold.
The second mold is formed with holding means that faces the ridge when the first mold and the second mold are closed, and moves in the opening / closing direction together with the second mold,
A first step of fixing the fixing member along the ridge when the first mold and the second mold are open;
A second step of injecting a foamable raw material into the cavity;
The first mold and the second mold are closed, the foamable raw material is foamed and filled into the cavity, and the hanging groove having a width wider than the surface is formed by the protrusions, and the fixing member A third step of forming the cushion body integrally embedded with
When the first mold and the second mold are opened and the cushion body is removed from the first mold, the holding means moves along with the movement of the second mold in the opening direction, and the ridges are moved. And a fourth step of applying a force in a direction away from the ridge to the surrounding foam. The holding means is formed so as to protrude into the cavity, and is capable of holding the fixing member by contacting the fixing member when the first mold and the second mold are closed,
In the fourth step, as the second mold moves in the opening direction, the holding means holds and moves the fixing member, and the convex member around the convex stripes moves to the foam through the fixing member. 2. The method of manufacturing a cushion body according to claim 1, wherein force is applied in a direction away from the strip. The fixing member is a steel wire, and the holding means includes a magnet;
In the fourth step, as the second mold moves in the opening direction, the magnet moves by magnetizing the steel wire, and the convex around the ridge is transferred to the foam through the steel wire. 3. The method of manufacturing a cushion body according to claim 2, wherein a force is applied in a direction away from the strip. The holding means can hold the fixing member by mechanically locking the fixing member;
In the fourth step, with the movement of the second mold in the opening direction, the holding means mechanically locks and moves the fixing member, and the foaming around the convex stripes via the fixing member. 3. The method of manufacturing a cushion body according to claim 2, wherein a force is applied to the body in a direction away from the ridges. The cushion body is integrally provided with a cloth-like auxiliary material having higher bending strength and rigidity than the foam on the back surface,
The holding means is a holding member protruding into the cavity;
In the first step, the holding member is locked in a holding hole formed in the auxiliary material,
In the third step, the auxiliary material is integrated with the foam,
In the fourth step, with the movement in the opening direction of the second type to move while the holding member holds the該補material, the said foam around the convex strip through該補material 2. The method of manufacturing a cushion body according to claim 1, wherein force is applied in a direction away from the ridge. The cushion body is integrally provided with a cloth-like auxiliary material having higher bending strength and rigidity than the foam on the back surface,
The holding means is a hook-and-loop fastener attached to the molding surface of the second mold;
In the first step, one surface of the auxiliary material is locked to the surface fastener,
In the third step, the other surface of the auxiliary material is integrated with the foam,
In the fourth step, with the movement in the opening direction of the second type move from said surface fastener holds the該補material, the said foam around the convex strip through該補material 2. The method of manufacturing a cushion body according to claim 1, wherein force is applied in a direction away from the ridge. The holding means is provided at a plurality of locations at intervals along the hanging groove,
In the fourth step, with the movement of the second mold in the opening direction, the holding means extends from the ridge to the foam around the ridge at a plurality of positions along the longitudinal direction of the hanging groove. The method for manufacturing a cushion body according to any one of claims 1 to 6, wherein a force is applied in a direction away from the cushion body. A foam cushion body manufacturing apparatus in which a long suspension groove is recessed on the surface and a rigid elongated fixing member is integrally embedded along the suspension groove.
A first mold that forms a front surface side of the cushion body, and a second mold that is openable and closable with respect to the first mold and forms a back surface side of the cushion body, the first mold and the first mold A foam molding die in which a cavity having a shape corresponding to the cushion body is formed when the two molds are closed;
The suspension groove can be formed on the molding surface of the first mold, and a protrusion having a wider tip than the base is formed protruding toward the second mold.
The second mold is formed with a holding means that is located at or near the portion facing the ridge when the first mold and the second mold are closed, and moves in the opening / closing direction together with the second mold. And
When the first mold and the second mold are open, the fixing member is fixed along the ridges, a foamable raw material is injected into the cavity, and the first mold and the second mold are Closes, foams the foamable raw material and fills the cavity, and the ridges form the hanging grooves wider than the surface and form the cushion body in which the fixing member is embedded integrally. When the first mold and the second mold are opened and the cushion body is removed from the first mold, the holding means moves and moves in the opening direction of the second mold. An apparatus for manufacturing a cushion body, characterized in that a force in a direction away from the ridges can be applied to the foam around the ridges. The holding means is formed so as to protrude into the cavity, and is capable of holding the fixing member by contacting the fixing member when the first mold and the second mold are closed,
As the second mold moves in the opening direction, the holding means moves while holding the fixing member, and a force is applied to the foam around the protruding strip in a direction away from the protruding strip through the fixing member. The apparatus for manufacturing a cushion body according to claim 8, wherein the apparatus is configured to be able to work. The fixing member is made of a magnetic material, and the holding means has a magnet capable of magnetizing the fixing member,
Along with the movement of the second mold in the opening direction, the magnet moves by magnetizing the fixing member, and a force is applied to the foam around the ridge in a direction away from the ridge through the fixing member. The apparatus for manufacturing a cushion body according to claim 9, wherein the apparatus is configured to be able to act. The holding means can hold the fixing member by mechanically locking the fixing member;
As the second mold moves in the opening direction, the holding means mechanically locks and moves the fixing member, and the foam around the ridge moves from the ridge to the foam through the fixing member. The apparatus for manufacturing a cushion body according to claim 9, wherein a force can be applied in a direction away from the cushion body. The cushion body is integrally provided with a cloth-like auxiliary material having higher bending strength and rigidity than the foam on the back surface,
The holding means is a holding member protruding into the cavity;
The holding member is locked in a holding hole formed in the auxiliary material, the auxiliary material is integrated with the foam, and the holding member moves the auxiliary material in the opening direction of the second mold. 9. The structure according to claim 8, wherein the movable body is moved while being held, and a force can be applied to the foam around the ridge in a direction away from the ridge through the auxiliary material. Cushion body manufacturing equipment. 13. The cushion body manufacturing apparatus according to claim 12, further comprising: an engaging portion that engages the auxiliary material when the auxiliary material passes through the tip of the holding member. 14. The apparatus for manufacturing a cushion body according to claim 13, wherein a tip of the locking portion is bent in a direction in which the cushion is taken out. The cushion body is integrally provided with a cloth-like auxiliary material having higher bending strength and rigidity than the foam on the back surface,
The holding means is a hook-and-loop fastener attached to the molding surface of the second mold;
One surface of the auxiliary material is locked to the surface fastener, the other surface of the auxiliary material is integrated with the foam, and the surface fastener holds the auxiliary material as the second mold moves in the opening direction. the move from the cushion according to claim 8, characterized in that it is the to be capable foam exerts a force in a direction away from the convex strip configuration around the convex strip through該補material Body manufacturing equipment. The holding means is provided at a plurality of locations at intervals along the hanging groove,
As the second mold moves in the opening direction, the holding means applies a force to the foam around the ridge in a direction away from the ridge at a plurality of positions along the longitudinal direction of the suspension groove. The apparatus for manufacturing a cushion body according to any one of claims 8 to 15, wherein the apparatus is configured to be capable of being configured.

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