JP3956102B2 - Integral foam molded product and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an integrally foamed molded product of a foam molded product such as a vehicle seat pad and a reinforcing fabric, and a method for manufacturing the same.
[0002]
[Prior art and problems to be solved by the invention]
Conventionally, as shown in FIG. 4, an integrated foam molded product in which a reinforcing fabric 2 such as coarse felt is integrated on the back surface and both side surfaces of a foam molded product 1 such as a flexible polyurethane foam during foam molding is an automotive seat pad. Etc. are used.
[0003]
However, the automotive seat pad in which the reinforcing fabric 2 is integrated on the back surface and both side surfaces of the foam molded article 1 as described above has a problem that the back surface rigidity of the side portion is high, and there is little feeling of deflection when seated. May occur.
[0004]
In this case, the reinforcing fabric is separated at both side edges of the back surface, and the reinforcing fabric 1a bonded to the back surface of the foam molded product 1 and the reinforcing fabrics 1b and 1b respectively bonded to the both side surfaces are interposed between them. Separating at the edge can solve the problem that the back surface rigidity is high and the bending feeling is low while giving a reinforcing effect, but foaming defects such as voids occur on the surface side of the separated edge There was often.
[0005]
That is, the foam molded product (vehicle seat pad) in which the reinforcing fabric is integrated as described above includes a lower mold 10a and an upper mold 10b as shown in FIG. 5, and both molds 10a and 10b are removed. A foaming material for flexible polyurethane foam is supplied to the cavity 11 of the foaming mold 10 formed by releasably joining to cause foaming. At this time, the reinforcing fabric 12 is provided on the inner and lower surfaces and both inner surfaces of the upper mold 10b in advance. The foaming raw material is infiltrated and foamed into the mesh (internal communication space) in the reinforcing fabric 12 by the rise of the foaming raw material by forming, and the reinforcing fabric 12 is made into a foam molded product (soft polyurethane foam sheet pad). It is a unitary joint. In this case, if the fabrics arranged on the inner lower surface and both inner side surfaces of the upper mold are continuous without being cut and separated at both edges of the inner lower surface and both inner side surfaces of the upper mold, Although foaming defects do not occur at both edges, as shown in FIG. 3, if the fabric is cut or separated at both edges, the gas flow generated during foaming is blocked at the end of 12b. , 12d, and foam defects are likely to occur as described above.
[0006]
The present invention has been made in view of the above circumstances, and has an integrated reinforcing fabric that has a high reinforcing effect, has an appropriate rigidity, has a good deflection, and has no foaming defects at the edge. An object of the present invention is to provide a foam molded article and a method for producing the same.
[0007]
[Means for Solving the Problems]
In order to achieve the above object, the present invention provides the following integral foam molded article and a method for producing the same.
[Claim 1] In an integrally foamed molded product obtained by integrally bonding a reinforcing fabric to the back surface and at least one side surface of a foam molded product such as a vehicle seat pad, the fabric is disposed on the back surface and the side surface. An integral foam molded article, wherein the fabric is spaced apart at the edge between the back surface and the side surface, and is integrally connected to each other via a bridging fabric at a plurality of locations,
[Claim 2] The integral foam molded article according to claim 1, wherein the foam molded article is a flexible polyurethane foam molded article,
[Claim 3] A foaming raw material is supplied into a cavity of a foaming mold formed by joining a lower mold and an upper mold so as to be detachable, and the inside of the upper mold Reinforcing fabrics are arranged on the lower surface and at least one inner side surface, and the foaming raw material is infiltrated and foamed into the fabrics by increasing the foaming, and the reinforcing fabric is provided on the back surface and at least one side surface of the foam molded product such as a vehicle seat pad. In the method for producing an integrally foamed molded article formed by integral joining, as the reinforcing fabric, a fabric disposed on the inner and lower surfaces of the upper mold and a fabric disposed on the inner surface are the inner surface and the side surface. A reinforcing fabric that is spaced apart at the edge between the two and is integrally connected to each other via a bridging fabric at a plurality of locations;
[Claim 4] The production method according to claim 3, wherein the foam molded article is a flexible polyurethane foam molded article.
[0008]
According to the present invention, when the integral foam molded article is manufactured, as the reinforcing fabric, the fabric disposed on the inner and lower surfaces of the upper mold and the fabric disposed on the inner side surface are between the inner surface and the side surface. By arranging reinforcing fabrics that are separated from each other at the edge and integrally connected to each other via a bridging fabric at a plurality of locations, the flow of gas generated during foaming is not blocked, as described above. There is no foaming defect such as a void, and an integrally foamed molded product in which a reinforcing fabric such as a good seat pad is integrally joined can be obtained.
[0009]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, an embodiment of the present invention will be described with reference to FIGS.
FIG. 1 illustrates an embodiment of the present invention for obtaining a flexible polyurethane foam vehicle seat pad, which includes a lower mold 10a and an upper mold 10b, and these molds 10a and 10b are detachably joined. The foam raw material for the flexible polyurethane foam is supplied to the cavity 11 of the foaming mold 10 formed by foaming, and the reinforcing fabric 12 is disposed in advance on the inner and lower surfaces and both inner surfaces of the upper mold 10b. The foaming raw material penetrates and foams into the mesh (internal communication space) in the reinforcing fabric 12 by the rise of the foaming raw material, and the reinforcing fabric 12 is integrally joined to the foam molded product (soft polyurethane foam sheet pad). . In this case, in the present invention, as the fabric disposed on the inner and lower surfaces of the upper mold and both inner surfaces, as shown in FIG. 2, the reinforcing fabric 12a disposed on the inner and lower surfaces of the upper mold and the upper mold Reinforcing fabrics 12b and 12b respectively disposed on both inner side surfaces use a fabric 12 that is integrally connected to each other via bridging fabrics 12c and 12c at a plurality of locations, and the bridging fabrics 12c and 12c are of the upper mold. It extends over the edge between the inner and lower surfaces and both inner surfaces, and the separation portions 12d and 12d between the back fabric 12a and the side fabrics 12b and 12b between the bridging fabrics 12c and 12c correspond to the edges. Is placed on the inner surface of the upper mold and foam-molded as described above.
[0010]
In this way, the back fabric and the side fabric are arranged in a state of being separated from each other at the edges of the inner and lower surfaces of the upper mold, and the foam (molded portion) is formed. In, a foamed molded article free from foaming defects can be obtained.
[0011]
In this case, as the reinforcing fabric, coarse felt, bolance, or the like is used, and the back fabric, the side fabric, and the bridging fabric are preferably integrally formed of the same material. It is preferable that the fabric has a uniform basis weight.
[0012]
In addition, when manufacturing the seat pad for motor vehicles, it is preferable that the width W of a bridging fabric is 10 mm or more.
[0013]
Moreover, as a foaming raw material for flexible polyurethane foam, those having a known composition are used, and foam molding can be performed under known molding conditions except that the reinforcing fabric is used.
[0014]
As shown in FIG. 3, the seat pad obtained by the above method is one in which reinforcing fabrics 12a and 12b are integrally joined to the back surface and both side surfaces of the seat pad (foam molded product) 20, respectively. The fabric 12a for the back surface and the fabric 12b for the side surface are separated from each other at the edge between the back surface and both side surfaces of the seat pad 20, and the fabrics 12a and 12b are integrally connected via the bridging fabric 12c. And exhibiting a good foaming state at the edge and no foaming defects such as voids.
[0015]
【The invention's effect】
According to the present invention, an edge portion between a reinforcing fabric bonded to the back surface and a reinforcing fabric bonded to the side surface has a good reinforcing effect and has an appropriate back surface rigidity and a sense of deflection. It is possible to provide an integrally foamed molded article such as a vehicle seat pad having no foaming defects at the corners).
[Brief description of the drawings]
FIG. 1 is a schematic cross-sectional view showing an example of a foam mold used in the present invention and a reinforcing fabric disposed on the foam mold.
FIG. 2 is a plan view showing an example of a reinforcing fabric used in the present invention.
FIG. 3 is a cross-sectional view showing an embodiment of an automobile seat pad obtained by the present invention.
FIG. 4 is a cross-sectional view of a conventional automobile seat pad.
FIG. 5 is a schematic cross-sectional view of a foam mold for explaining a conventional method.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Foam mold 10a Lower mold | type 10b Upper mold | type 11 Cavity 12 Reinforcement fabric 12a Back surface fabric 12b Side surface fabric 12c Bridging fabric 12d Separation part 20 Seat pad

Claims (4)

In an integrally foamed molded product obtained by integrally bonding a reinforcing fabric to the back surface and at least one side surface of a foam molded product such as a vehicle seat pad, the fabric disposed on the back surface and the fabric disposed on the side surface are An integral foamed molded article characterized by being separated from each other at an edge portion between the back surface and the side surface and integrally connected to each other via a bridging fabric at a plurality of locations. The integral foam molded article according to claim 1, wherein the foam molded article is a flexible polyurethane foam molded article. The lower mold and the upper mold are provided, and the foaming raw material is supplied into the cavity of the foaming mold formed by releasably joining the two molds, and foamed, and the inner and lower surfaces of the upper mold and at least one inside Reinforcing fabrics are arranged on the side surfaces, and the foaming material is infiltrated and foamed into the fabrics by increasing the foaming, and the reinforcing fabrics are integrally joined to the back surface and at least one side surface of the foam molded product such as a vehicle seat pad. In the method for producing an integral foam molded article, the reinforcing fabric is a fabric disposed on the inner and lower surfaces of the upper mold and a fabric disposed on the inner side surface between the inner surface and the side surface. And a reinforcing fabric that is separated from each other and integrally connected to each other via a bridging fabric at a plurality of locations. The production method according to claim 3, wherein the foam molded article is a flexible polyurethane foam molded article.

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