JP3962619B2 - Vehicle seat manufacturing apparatus and manufacturing method - Google Patents

Description

[0001]
[Industrial application fields]
  The present invention relates to an apparatus and a method for manufacturing a vehicle seat, and more particularly, to an apparatus and a method for manufacturing a vehicle seat that do not use staples for joining a skin material and a bottom plate.
[0002]
[Prior art]
  As shown in FIG. 11, the vehicle seat 100 disposed in a motorcycle or the like is formed by placing a cushion material 120 on a bottom plate 130 and covering it with a skin material 110. The terminal portion 110 a of the skin material 110 is fixed to the back surface side of the bottom plate 130 by a staple 140.
[0003]
  By the way, in various industrial fields, when a part is required to have rigidity, a molded article of a fiber reinforced resin, which is lighter than metal and easy to manufacture, is used. Also, resin molded products of fiber reinforced resin are used in parts of automobiles and motorcycles.
[0004]
[Problems to be solved by the invention]
  Also for the bottom plate of the vehicle seat, the use of the fiber reinforced resin is preferable because rigidity can be ensured without increasing the weight. However, as described above, since the end portion of the skin material is joined to the bottom plate by staples, in the case of the bottom plate made of resin mixed with fibers, the bottom plate is cracked by the impact caused by the tucker and the staples. Could occur.
[0005]
  In addition, when fixing the end of the skin material to the bottom plate with staples, the staple material must be driven by the tucker while holding the skin material in an appropriate position, so skill is required to perform the work efficiently. It had been.
[0006]
  The objective of this invention is providing the manufacturing apparatus and manufacturing method of a vehicle seat which can manufacture the vehicle seat by which the terminal process of the skin material was made suitably, without using a staple.
[0007]
  Another object of the present invention is to provide a vehicle seat manufacturing apparatus and method that can manufacture a vehicle seat that includes a bottom plate that is lightweight and has high rigidity, and that is suitable for terminal treatment of the skin material. There is to do.
[0008]
  Furthermore, an object of the present invention is to provide a vehicle seat manufacturing apparatus and a manufacturing method capable of manufacturing a vehicle seat in which the end treatment of the skin material is suitably performed without using staples with high productivity. There is to do.
[0009]
[Means for Solving the Problems]
  According to the vehicle seat manufacturing apparatus S according to claim 1, the above-described problem is provided in the vehicle seat manufacturing apparatus that includes the bottom plate 13 and is covered with the skin material 11 having the back base fabric. And a presser that descends from above the vacuum concave mold 1 and presses the end region 11a of the skin material 11 disposed on the vacuum concave mold 1 between the opening peripheral edge of the vacuum concave mold 1. Until the frame 2, the pressurizing means 4 that pressurizes after disposing the cushion material 12 and the bottom plate 13 on the skin material 11 of the vacuum concave mold 1, and at least a part of the back side of the bottom plate 13 are melted. To heatIt consists of an electrothermal welder that can be raised and lowered on the vacuum concave mold 1The back base fabric of the skin material 11 is in contact with the heating means 5 and the melted portion of the bottom plate 13.The holding frame 2 and a standing wall 1b provided on the peripheral edge of the opening of the vacuum concave mold 1 are arranged at a predetermined interval and extend from the peripheral edge of the opening toward the inside of the vacuum concave mold 1. By the extending means 6b,The skin material folding means 6 for folding the end region 11 a of the skin material 11 into the back surface side of the bottom plate 13, and the back surface side of the bottom plate 13 and the terminal region 11 a of the skin material 11Lower the heating means 5This is solved by including a crimping means for crimping.
[0010]
  In the vehicle seat manufacturing apparatus S of the present invention, the presser frame 2 isForward when up It is preferable to face the direction.
[0011]
  Thus, by making the front of the presser frame 2 face upward further, it is possible to secure a wider working space in the vertical direction.
[0012]
  The vehicle seat manufacturing method of the present invention is a vehicle seat manufacturing method including a bottom plate 13 and covered with a skin material 11 having a back base fabric, and the skin material 11 is disposed in the vacuum concave mold 1. And a step of lowering the presser frame 2 from above the vacuum concave mold 1 and pressing the end region 11a of the skin material 11 disposed on the vacuum concave mold 1 between the opening peripheral edge of the vacuum concave mold 1 and A step of vacuum forming the skin material 11, a step of disposing and pressurizing the cushion material 12 and the bottom plate 13 on the vacuum-formed skin material 11, and at least a part of the back side of the bottom plate 13 Until it meltsBy heating means 5 that can be raised and lowered on the vacuum concave mold 1Heating, andA step of temporarily raising the heating means 5 after the heating step;Folding the end region 11a of the skin material 11 to the back side of the bottom plate 13 so that the back base fabric of the skin material 11 is in contact with the melted portion of the bottom plate 13;In the step of raising the heating means 5, the heating means 5 is lowered after being cooled,Pressurizing the end region 11a of the skin material 11 positioned in the melted portion of the bottom plate 13 so that the molten resin in which the bottom plate 13 is melted penetrates into the back base fabric; And a step of cooling the terminal region 11a of the skin material 11 until the molten resin that has permeated the cloth is solidified.
[0013]
  In addition, in the said manufacturing method, after the process of vacuum-forming the said skin material 11, among the terminal area | regions 11a of the skin material 11 fixed by the said presser frame 2, the said opening frame 2 and the opening peripheral part of the said vacuum concave mold 1 A trimming process for separating the part sandwiched between the other part from the other part,After the trimming step, a presser frame raising step in which the front of the presser frame faces upward when the presser frame is raised and raised.You may make it do.
[0014]
  As described above, according to the vehicle seat manufacturing apparatus S and the manufacturing method of the present invention, at least a part on the back surface side of the bottom plate 13 particularly in the terminal processing of the skin material 11 in the vehicle seat manufacturing process.Can be moved up and down on the vacuum concave mold 1 which is heated until it melts.It is melted by the heating means 5 and is folded and attached so that the back base fabric of the skin material 11 is in contact with the melted portion. The molten resin penetrates into the back base fabric, solidifies and is integrated.Then, the heating means 5 is cooled and then lowered to press the end region 11a of the skin material 11Thus, the end region 11 a of the skin material 11 is configured to be fixed to the back surface side of the bottom plate 13, and the skin material can be used without using the staple that has been conventionally used for the terminal treatment of the skin material 11. 11 terminal processes can be performed.Moreover, a wider working space can be secured in the up-down direction by the presser frame whose front is directed upward when it is raised.
[0015]
  Therefore, it is possible to employ the bottom plate 13 made of fiber reinforced resin, which has been difficult to use in the past because it is vulnerable to local impact. This makes it possible to ensure rigidity without increasing the weight of the vehicle seat.
[0016]
  Furthermore, according to the vehicle seat manufacturing apparatus S and the manufacturing method of the present invention,The heating means 5 can heat the entire circumference of the peripheral edge of the bottom plate 13 with no time difference, and can keep the state of the molten resin uniform.On the back base fabric of the skin material 11UniformlyWhen infiltrating, solidifying this and joining the skin material 11 and the bottom plate 13,The heating means 5 is also used as a crimping meansTherefore, it is possible to obtain a vehicular seat that is excellent in appearance without the junction with the bottom plate 13 appearing on the surface side of the skin material 11.
[0017]
  In addition, according to the vehicle seat manufacturing apparatus S and the manufacturing method of the present invention, the skin material 11 can be molded, the skin material fixed, in one place, without changing the apparatus and location for each process of manufacturing the vehicle seat. Assembling of members, pressurization, and terminal processing can be performed, and it is possible to efficiently manufacture a vehicle seat without the need for conveyance and the like.
[0018]
  In addition, as described above, since all the processes for manufacturing the vehicle seat can be performed in one place, a large-scale device for moving work in progress and a place for installing various devices are required. It is not possible to effectively use the limited space.
[0019]
  Furthermore, since the product is completed in one place, it is possible to produce a variety of products in small quantities, meet various demands for vehicle seats, and produce the required amount when necessary. .
[0020]
DETAILED DESCRIPTION OF THE INVENTION
  Hereinafter, an embodiment of the present invention will be described with reference to the drawings. The members, arrangements, and the like described below are not intended to limit the present invention and can be variously modified within the scope of the gist of the present invention.
[0021]
  FIG. 1 to FIG. 10 show an embodiment of the present invention. FIG. 1 is an explanatory view showing a vehicle seat manufacturing apparatus according to the present invention. FIG. FIG. 3 is an explanatory diagram showing a process of vacuum forming the skin material, FIG. 4 is an explanatory diagram showing a process of trimming a part of the skin material fixed by the presser frame, and FIG. 5 is a cushion material and a bottom. FIG. 6 is an explanatory diagram showing a process of pressurizing the cushion material and the bottom plate, FIG. 7 is an explanatory diagram showing a process of heating a part of the back side of the bottom plate, and FIG. Is an explanatory view showing the process of folding the end portion of the skin material on the back surface side of the bottom plate, FIG. 9 is an explanatory diagram showing the process of pressurizing and cooling the end portion of the skin material folded on the back surface side of the bottom plate, FIG. 10 is a flowchart showing the flow of the manufacturing process of the vehicle seat. It is a chromatography chart.
[0022]
  In this example, description will be made based on an example in which the vehicle seat is applied to a vehicle seat used in a motorcycle. Note that the vehicle seat includes not only motorcycles, that is, those used on land motorcycles and scooters, but also seats for snowmobiles and water motorcycles, and also includes three-wheel buggy vehicles, straddle-type vehicles, or construction machinery seats. Including vehicle seats.
[0023]
  The vehicle seat of this example includes a skin material 11, a cushion material 12, and a bottom plate 13. The skin material 11 is comprised from the surface material and the back base fabric (not shown).
[0024]
  The surface material of the skin material 11 is made of a water-resistant material such as PVC (polyvinyl chloride resin). Further, the back base fabric is formed of knitted fabric or a wooly processed product such as polyester or nylon, cotton, non-woven fabric, net or the like.
[0025]
  A knitted fabric is a knitted fabric in which yarns are knitted in a loop. In addition, the wooly processed product is formed from a synthetic fiber yarn that has been provided with stretchability and bulkiness. As described above, all of the cloth materials constituting the back base cloth 12 have a space between the fibers.
[0026]
  The vehicle seat of this example heats the bottom plate 13 and attaches the terminal portion 11a of the skin material 11 to the bottom plate 13 through a molten resin in which the bottom plate 13 is melted. In addition, since the cloth material constituting the back base fabric has a space between the fibers, the molten resin sufficiently enters the back base fabric, and the adhesive force between the bottom plate 13 and the skin material 11 is ensured. The
[0027]
  The cushion material 12 is formed of a flexible foam material such as urethane foam, PP (polypropylene) foam, or PE (polyethylene) foam, and is placed on the bottom plate 13.
[0028]
  The cushion material 12 is covered with the skin material 11. The cushion material 12 and the skin material 11 may be formed as separate bodies, or the cushion material 12 and the skin material 11 may be integrally formed.
[0029]
  The bottom plate 13 is formed of, for example, PP (polypropylene), ABS resin, or the like. The bottom plate 13 is formed by using PPG (polypropylene with glass fiber) or PPT (polypropylene with filler) that is a fiber reinforced resin. By using it, rigidity can be secured without increasing the weight of the bottom plate 13, which is preferable. For example, carbon fibers are mixed in the PPT as reinforcing fibers.
[0030]
  As shown in FIG. 1, the vehicle seat manufacturing apparatus S of this example includes a vacuum concave mold 1, a presser frame 2 that holds a terminal portion 11 a of a skin material 11 disposed in the vacuum concave mold 1, and a skin material 11. A heater 3 for heating, a pressurizing means 4 for pressurizing a structural member of the vehicle seat disposed in the vacuum concave mold 1, a heating means 5 for heating until at least a part of the back surface side of the bottom plate 13 is melted, A skin material folding means 6 for folding the end portion 11a of the skin material 11 to the back surface side of the bottom plate, and a crimping means for crimping the back surface side of the bottom plate 13 and the terminal portion 11a of the skin material 11 are provided.
[0031]
  Although not shown in FIG. 1, the vehicle seat manufacturing apparatus S of this example includes trim means 7 for cutting a part of the peripheral edge of the skin material 11.
[0032]
  The vacuum concave mold 1 is evacuated from the skin material 11 and formed into a predetermined shape, and the components of the vehicle seat are disposed and assembled. A suction hole connected to the vacuum device V is provided on the surface of the vacuum concave mold 1. In this example, the vacuum apparatus V is illustrated only in FIG.
[0033]
  A standing wall portion 1 b is provided in the opening of the vacuum concave mold 1. The upright wall portion 1 b is related to the folding processing of the skin material 11 together with the skin material folding means 6, and is provided upright at the opening of the vacuum concave mold 1. The standing wall portion 1b is configured such that when the terminal portion 11a of the skin material 11 is folded and fixed to the bottom plate 13, a portion serving as a folding margin is located. For this reason, a desired folding | turning allowance can be ensured by adjusting the height of the standing wall part 1b.
[0034]
  Further, the standing wall 1b is provided with a notch 1c for disposing a skin material folding means 6 described later at a predetermined interval. The cutout portion 1c is formed so that the extending portion 6b of the skin material folding means 6 can be disposed. The notch 1c is formed by, for example, notching the standing wall 1b with a predetermined width at a predetermined interval.
[0035]
  For this reason, it is preferable that the standing wall portion 1b is made of a material that can easily form the cutout portion 1c and the like. For example, resin or wood is used as the material of the standing wall 1b.
[0036]
  In addition, when a porous porous electroformed vacuum forming die is used as the vacuum concave die 1, when vacuuming is performed, the skin material 11 is adsorbed to the die surface from all directions and can be uniformly adhered to the die surface. This is preferable.
[0037]
  In addition, when a porous electroformed vacuum forming die is used, a fine texture pattern or a complicated figure can be reproduced faithfully on the mold surface, and a molded product with high design can be obtained.
[0038]
  The presser frame 2 seals the skin material 11 over the entire circumference of the vacuum concave mold 1, and is moved in the vertical direction above the vacuum concave mold 1. The presser frame 2 is formed to have substantially the same shape as the opening peripheral edge 1 a of the vacuum concave mold 1, that is, the upper surface of the standing wall 1 b in this example, and is pressed by the opening peripheral edge 1 a of the vacuum concave mold 1. The presser frame 2 is configured to be in close contact with the opening peripheral edge 1 a of the vacuum concave mold 1 and sandwich and fix the skin material 11 between the vacuum peripheral mold 1 and the opening peripheral edge 1 a.
[0039]
  The presser frame 2 is suspended from the frame 9 via a lifting / lowering device 8 including a rod 2a and an air cylinder connected to the rod 2a. The lifting / lowering device 8 is connected to a pressure supply source (in this example, an air supply source), and is operated by air supply so that the presser frame 2 can be lifted / lowered by extending / contracting the rod 2a.
[0040]
  In addition, when the presser frame 2 rises to the uppermost part, it is possible to secure a wider working space in the vertical direction by making the front of the presser frame 2 face upward. For this purpose, for example, rods 2a may be provided at a total of four positions on the left and right sides of the presser frame 2, and when the presser frame 2 is raised to the top, the rod 2a located on the front side may be further raised.
[0041]
  In addition, in order to hold | maintain the said presser frame 2 more reliably, it is good also as a structure which provided the clamp means. As a specific configuration of the clamping means, for example, a base portion disposed in the vacuum concave mold 1, a driving device including an air cylinder provided in the base portion, a link mechanism connected to a piston rod of the air cylinder, and a link mechanism And a plurality of presser portions provided on the shaft portion, and a plurality of them are provided on the opening side of the vacuum concave mold 1.
[0042]
  The driving device of the clamping means is connected to a pressure supply source via a conduit, and is operated by air supply to rotate the shaft portion via the link mechanism, thereby changing the direction of the pressing portion, By moving the shaft portion downward, the presser portion is lowered and pressed against the opening peripheral edge portion 1 a of the vacuum concave mold 1. By pressing the presser frame 2 using the clamping means, the terminal portion 11a of the skin material 11 can be more reliably fixed.
[0043]
  The heater 3 is configured such that a plurality of heating lamps 3b are disposed on a planar holding body 3a so as to face the vacuum concave mold 1 side. The heater 3 is for heating the skin material 11 before the skin material 11 is evacuated. By heating the skin material 11 with the heater 3, the skin material 11 becomes flexible and can be molded well in the vacuum concave mold 1.
[0044]
  The heater 3 is disposed on a slide frame (not shown), and is configured to move within the slide frame using an air cylinder as a drive source so as to advance or retreat above the vacuum concave mold 1. ing.
[0045]
  As the slide mechanism, for example, the heater 3 is moved back and forth by sliding a roller disposed on the heater 3 side along a rail on the slide frame side. It is preferable to provide a stopper at the end of the rail and stop the movement of the heater 3 when the roller of the heater 3 reaches the position of the stopper.
[0046]
  In addition, as a heating means which comprises the heater 3, it is good also as a structure which provided the heating wire instead of the above-mentioned heating lamp. In addition, after heating the skin material 11, electricity supply to a heating lamp or a heating wire is stopped.
[0047]
  The pressurizing means 4 is suspended from the frame 9 via a rod 4a and an elevating device 8 comprising an air cylinder connected to the rod 4a. The pressurizing means 4 can be moved up and down on the vacuum concave mold 1 by the operation of the lifting device 8 in the same manner as the presser frame 2 described above, and pressurizes the constituent members of the vehicle seat disposed in the vacuum concave mold 1. It is configured.
[0048]
  As the heating means 5 for the bottom plate 13, in this example, a frame-shaped heating element that matches the peripheral shape of the bottom plate 13 is used. The heating means 5 is suspended from the frame 9 via a lifting device 8 including a rod 5a and an air cylinder connected to the rod 5a.
[0049]
  The heating means 5 can be moved up and down on the vacuum concave mold 1 by the operation of the lifting and lowering device 8, similar to the presser frame 2 and pressurizing means 4, and on the back side of the bottom plate 13 disposed in the vacuum concave mold 1. It descend | falls until it contact | abuts, and it is comprised so that the predetermined site | part of the back surface of the bottom plate 13 may be heated.
[0050]
  Here, a specific configuration of the bottom plate heating means 5 will be described. As heating means 5IsIn this example, an electrothermal welder is used as the heating means 5.
[0051]
  As shown in FIG. 7, the electrothermal welder as the heating means 5 is configured to include a heating unit 5b incorporating a heater. The heating part 5b is made of a metal having high thermal conductivity, and is made of, for example, aluminum. And it is comprised so that the object contact | abutted to the heating part 5b may be heated when the heater incorporated in the heating part 5b generates heat.
[0052]
  In addition, it is preferable to provide a non-coated film such as a fluororesin on the heating unit 5b, so that a non-heated melt or the like hardly adheres to the heating unit 5b. Moreover, even if a melt adheres, it can be easily removed.
[0053]
  As described above, the heating means 5 may be formed in a frame shape that matches the peripheral shape of the bottom plate 13 or may be formed in a shape obtained by dividing the frame shape. Thus, when the heating means 5 has a divided shape, the shape of each heating means 5 may be any shape. The shape of each heating means 5 is formed in shapes, such as a cross-sectional rectangle, a cross-sectional circle, a cross-sectional ellipse, a cross-sectional polygon, etc.
[0054]
  Since it is configured as described above, the heating means 5 heats the entire circumference of the peripheral edge of the bottom plate 13 without a time difference. By heating without any time difference over the entire periphery of the peripheral edge of the bottom plate 13, the state of the molten resin can be kept uniform, and the molten resin is applied to the back base fabric of the skin material 11 in a subsequent step. Can be uniformly permeated.
[0055]
  In addition to the above configuration, a configuration in which a plurality of electrothermal welders are arranged in accordance with the shape of the peripheral edge of the bottom plate 13 may be used. In this case, control is performed so that a plurality of electrothermal welders move toward the bottom plate 13 without a time difference and a heating operation is performed.
[0056]
  As described above, when the bottom plate 13 is heated by the heating unit 5, a resin melting portion is formed in the bottom plate 13. The resin melting part is provided along the peripheral edge of the bottom plate 13.
[0057]
  A plurality of resin melting portions may be provided at predetermined intervals along the peripheral edge portion of the bottom plate 13, or may be configured to be continuously provided in a band shape without a predetermined interval. . Moreover, it is good also as a structure which provided the strip | belt-shaped resin melt part in 2 rows or 2 or more rows.
[0058]
  The place where the resin melted portion is formed is not limited to the peripheral edge portion of the bottom plate 13 but may be the back side surface of the seating surface portion of the bottom plate 13. In addition, you may make it provide the resin fusion | melting part in both the peripheral edge part of the bottom plate 13, and the back side surface of a seat surface part. Thereby, the terminal part 11a of the skin material 11 can be joined to both the peripheral edge part of the bottom plate 13, and the back side surface of a seat surface part, and it becomes possible to obtain high joining property.
[0059]
At this time, by continuously providing the resin melted portion on the peripheral edge side and the resin melted portion on the back side surface of the seat surface portion, the skin material 11 is also provided on the boundary portion between the peripheral edge portion and the back side surface of the seat surface portion. The skin material 11 and the bottom plate 13 can be joined with high adhesion.
[0060]
  Also,When the heating means 5 is an electrothermal welder, the electrothermal welder as the heating means 5 can also be used as a crimping means and a cooling means for the terminal portion 11a of the skin material 11.
[0061]
  That is, after heating the bottom plate 13, the temperature of the heating portion of the electrothermal welder is gradually lowered by stopping energization of the electrothermal welder. Then, when the temperature is sufficiently lowered, the electrothermal welder whose temperature is lowered is lowered toward the bottom plate 13 again.
[0062]
  Then, as shown in FIG. 9, an electrothermal welder having a lowered temperature is pressed against the terminal portion 11 a of the skin material 11 attached to the melted portion on the back surface side of the bottom plate 13. In this manner, the end portion 11a of the skin material 11 can be cooled while being crimped to the bottom plate.
[0063]
  A plurality of skin material folding means 6 of this example are provided in the vacuum concave mold 1 at a predetermined interval. The skin material folding means 6 includes a base portion 6a that is fixed to the vacuum concave mold 1 and an extending portion 6b that extends from the base portion 6a.
[0064]
  The skin material folding means 6 is connected to a driving device composed of an air cylinder, and by the power of the air cylinder, the extending part 6b passes through the notch part 1c of the standing wall part 1b and moves inward of the vacuum concave mold 1, The terminal portion 11 a of the material 11 is configured to be folded toward the vacuum concave mold 1.
[0065]
  The trim means 7 includes a blade portion 7 a and is configured to cut the skin material 10. In this example, as shown in FIG. 4, the trim means 7 is configured not to be incorporated in the vehicle seat manufacturing apparatus S, and the skin material 11 is trimmed manually by an operator.
[0066]
  As described above, the trim means 7 may be incorporated in the vehicle seat manufacturing apparatus S instead of performing the trim manually. In this case, as the trim means 7, a frame-shaped blade portion that can come into contact with the upper portion of the standing wall portion 1 b is disposed so as to be movable up and down, and the blade portion is lowered and pressed against the standing wall portion 1 b, It is set as the structure which can cut | disconnect the skin material 10 between.
[0067]
  In this example, the presser frame 2, the heater 3, the pressurizing means 4, the heating means 5, the skin material folding means 6, and the clamping means are described as being operated by an air cylinder. Of course, other drive mechanisms may be used.
[0068]
  Next, the manufacturing method of the vehicle seat of this example will be described based on FIGS. The vehicle seat is manufactured by operating the manufacturing apparatus S according to a predetermined procedure.
[0069]
  The operation of the manufacturing apparatus S is performed by automatic control or manual control. In the case of automatic control, the heating state is monitored by a temperature sensor, the processing time is measured by a timer, and each means is automatically operated based on information from these sensors and the timer.
[0070]
  When the manufacturing apparatus S is operated by manual control, an operation panel (not shown) is provided in the vicinity of the manufacturing apparatus S, and each unit is operated by turning on a plurality of switches of the operation panel. So that
[0071]
  The switch is provided corresponding to each of the vacuum concave mold 1, the holding frame 2, the heater 3, the pressurizing means 4, the heating means 5, the skin material folding means 6, the clamping means, and the trim means, and operates the switch. Thus, each means is configured to be activated or deactivated. In addition, you may make it control using a timer about the start from the operation | movement start of each means.
[0072]
  Here, an example of the flow of the manufacturing process is shown in the flowchart of FIG. In the first step S 1, the skin material 11 is set in the vacuum concave mold 1. In the second step S2, the presser frame 2 is lowered and the skin material 11 is fixed. In the third step S <b> 3, the skin material 11 is heated by the heater 3.
[0073]
  In the fourth step S4, vacuum forming of the skin material 11 is performed. In 5th step S5, the part pinched | interposed between the said press frame and the opening peripheral part of the said vacuum concave shape among the terminal area | regions of the skin material 11 is cut off from another part.
[0074]
  In the sixth step S6, the cushioning material 12 and the bottom plate 13 are set, and in the seventh step S7, the pressurizing means 4 is lowered and the cushioning material 12 and the bottom plate 13 are pressed.
[0075]
  In the eighth step S <b> 8, the heating means 5 is lowered to heat a predetermined portion of the bottom plate 30. In the ninth step S9, the heating means 5 is temporarily raised, and the end portion 11a of the skin material 11 is folded back to the bottom plate 13 side by the skin material folding means 6.
[0076]
  In the tenth step S <b> 10, the cooled heating means 5 is lowered again to cool the terminal portion 11 a of the skin material 11 while being crimped to the bottom plate 13. The manufacturing apparatus S includes at least a second step S2, a third step S3, a fourth step S4, a fifth step S5, a seventh step S7, an eighth step S8, among the above steps. The ninth step S9 and the tenth step S10 are processed.
[0077]
  Next, each process of the manufacturing method of the vehicle seat of this invention is demonstrated, referring drawings. First, as shown in FIG. 2, the skin material 11 is disposed in the vacuum concave mold 1. At this time, the end of the skin material 11 of the skin material 11 may be temporarily fixed by a clip attached to the vacuum concave mold 1.
[0078]
  Then, the presser frame 2 is lowered from above the vacuum concave mold 1, and the terminal portion 11 a of the skin material 11 disposed in the vacuum concave mold 1 is pressed. Furthermore, when the clamp means is provided, the presser frame 2 is fixed by the clamp means. In this way, the skin material 11 is pressed and fixed at the opening peripheral edge 1a of the vacuum concave mold 1 with a uniform force.
[0079]
  Further, a heater 3 is disposed above the vacuum concave mold 1. At this time, since the end portions of the skin material 11 are uniformly held by the presser frame 2 and the clamping means, even if the skin material 11 is softened by heating by the heater 3, a part of the skin material 11 is stretched and deformed. Thus, the heat treatment can be suitably performed.
[0080]
  Next, energization of the heater 3 is stopped, and the heater 3 is retracted from above the vacuum concave mold 1. Then, as shown in FIG. 3, the skin material 11 set in the vacuum concave mold 1 is vacuumed and molded. At this time, a texture pattern or the like may be formed on the vacuum concave mold 1 and transferred to the skin material 11.
[0081]
  When the skin material 11 is evacuated in the vacuum concave mold 1, as shown in FIG. 4, between the holding frame 2 and the opening peripheral edge 1 a of the vacuum concave mold 1 among the terminal portions 11 a of the skin material 11 by the trim means 7 A process of separating the portion sandwiched between the two is performed.
[0082]
  By trimming the skin material 11, the terminal portion 11 a of the skin material 11 is released from being fixed by the presser frame 2. Thereby, it becomes possible to bend the terminal part 11a of the skin material 11 to the bottom plate 13 side and fix it to the bottom plate 13 in a subsequent process. After trimming the skin material 11, the clamping means is released and the presser frame 2 is raised.
[0083]
  Next, as shown in FIG. 5, the cushion material 12 and the bottom plate 13 are placed on the vacuum-formed skin material 11. Next, as shown in FIG. 6, pressure is applied from the bottom plate 13 side by the pressurizing means 4.
[0084]
  Then, with the pressure applied by the pressurizing means 4, as shown in FIG. 7, the heating means 5 descends and comes into contact with the bottom plate 13, and the resin at the peripheral edge on the back surface side of the bottom plate 13 is melted. . Heating is performed until the surface of the bottom plate 13 reaches 200 to 210 ° C.
[0085]
  When the bottom plate 13 is heated to provide the resin melting portion, the heating means 5 is pulled up. Then, the skin material folding means 6 is operated, the terminal portion 11a of the skin material 11 is folded to the bottom plate 13 side, and is attached to the heated portion of the bottom plate 13.
[0086]
  That is, when the heating of the bottom plate 13 is completed, the skin material 11 is in a state in which the terminal portion 11a is along the standing wall portion 1b as shown in FIG. Thus, when the terminal part 11a of the skin material 11 is in a state along the standing wall part 1b, the extending part 6b of the skin material folding means 6 penetrates the notch part 1c of the standing wall part 1b, and is vacuumed. Move to the concave mold 1 side.
[0087]
  Thereby, the terminal part 11a of the skin material 11 is pushed to the vacuum concave mold 1 side, and the terminal part 11a is folded back as shown in FIG. At this time, the pressure is continuously applied to the cushion material 12 and the bottom plate 13 by the pressurizing means 4.
[0088]
  When the terminal portion 11a of the skin material 11 is folded back by the skin material folding means 6 and disposed so as to overlap the resin melting portion, the terminal portion 11a of the skin material 11 is then pressurized. In this example, as shown in FIG. 9, the heating means 5 whose temperature has been sufficiently lowered is lowered again toward the bottom plate 13 to perform pressurization.
[0089]
  By applying pressure, the back base fabric of the skin material 11 is pressure-bonded to the resin melted portion. The cloth material constituting the back base fabric of the skin material 11 is made of knitted fabric or wooly processed product and has a space between the fibers. The molten resin in which the peripheral edge portion of the plate 13 is melted penetrates.
[0090]
  At this time, when the heating means 5 whose temperature has been sufficiently lowered comes into contact, the terminal portion 11a of the skin material 11 is cooled, and the molten resin that has penetrated into the back base fabric of the skin material 11 is solidified.
[0091]
  In this way, the molten resin that has permeated the back base fabric of the skin material 11 is solidified, and the back base fabric and the bottom plate 13 permeate the back base fabric and are integrated through the solidified resin. In this way, the end portion 11 a of the skin material 11 is fixed to the peripheral edge portion of the bottom plate 13.
[0092]
  Finally, the pressurizing means 4 that pressurizes the cushion material 12 and the bottom plate 13 is raised. Thus, in the manufacturing apparatus S of this example, since the terminal treatment of the skin material 11 is performed while being pressurized by the pressurizing means 4, the skin material 11 can be attached to the bottom plate 13 with an appropriate tension. It is possible to obtain a vehicle seat that is good in appearance.
[0093]
【The invention's effect】
  As described above, according to the vehicle seat manufacturing apparatus and the manufacturing method of the present invention, at least a part on the back surface side of the bottom plate particularly in the terminal treatment of the skin material in the vehicle seat manufacturing process.Can be moved up and down on the vacuum recessIt is melted by the heating means, folded and attached so that the back base fabric of the skin material is in contact with the melted portion, the molten resin penetrates into the back base fabric, solidifies and is integrated,By lowering the heating means after cooling, and pressurizing the terminal area of the skin materialThe terminal part of the skin material is configured to be fixed to the back side of the bottom plate, and it is possible to perform the terminal processing of the skin material without using the staple that has been used for the terminal processing of the skin material conventionally. Become.Moreover, a wider working space can be secured in the up-down direction by the presser frame whose front is directed upward when it is raised.
[0094]
  Therefore, it is possible to employ a bottom plate made of fiber reinforced resin, which has been difficult to use in the past because it is vulnerable to local impact. This makes it possible to ensure rigidity without increasing the weight of the vehicle seat.
[0095]
  Furthermore, according to the vehicle seat manufacturing apparatus and method of the present invention,The heating means 5 can heat the entire circumference of the peripheral edge of the bottom plate without a time difference, and can keep the state of the molten resin uniform.On the back base fabric of the skin material 11UniformlyWhen infiltrating, solidifying this and joining the skin material 11 and the bottom plate 13,Combine heating means as pressure bonding meansTherefore, it is possible to obtain a vehicular seat that is excellent in appearance without the junction with the bottom plate 13 appearing on the surface side of the skin material 11.
[0096]
  Further, according to the vehicle seat manufacturing apparatus and method of the present invention, the skin material can be molded, the skin material fixed, and the member set in one place without changing the device and the location for each process of manufacturing the vehicle seat. Thus, the vehicle seat can be efficiently manufactured without the need for transportation and the like.
[0097]
  In addition, as described above, since all the processes for manufacturing the vehicle seat can be performed in one place, a large-scale device for moving work in progress and a place for installing various devices are required. It is not possible to effectively use the limited space.
[0098]
  Furthermore, since the product is completed in one place, it is possible to produce a variety of products in small quantities, meet various demands for vehicle seats, and produce the required amount when necessary. .
[Brief description of the drawings]
FIG. 1 is an explanatory view showing a vehicle seat manufacturing apparatus according to the present invention.
FIG. 2 is an explanatory view showing a process of arranging and heating a skin material in a vacuum concave mold.
FIG. 3 is an explanatory view showing a process of vacuum forming a skin material.
FIG. 4 is an explanatory view showing a process of trimming a part of the skin material fixed by the presser frame.
FIG. 5 is an explanatory view showing a process of disposing a cushion material and a bottom plate.
FIG. 6 is an explanatory view showing a process of pressurizing the cushion material and the bottom plate.
FIG. 7 is an explanatory diagram showing a process of heating a part of the back surface side of the bottom plate.
FIG. 8 is an explanatory view showing a process of folding the end portion of the skin material on the back surface side of the bottom plate.
FIG. 9 is an explanatory view showing a process of pressurizing and cooling the end portion of the skin material folded to the back surface side of the bottom plate.
FIG. 10 is a flowchart showing a flow of a vehicle seat manufacturing process.
FIG. 11 is an explanatory diagram showing a conventional example.
[Explanation of symbols]
  1 Vacuum concave type
  2 Presser frame
  3 Heater
  4 Pressurizing means
  5 Heating means
  6 Skin material folding means
  7 Trim means
  8 Lifting device
  9 frames
  11 Skin material
  12 Cushion material
  13 Bottom plate
  S Vehicle seat manufacturing equipment

Claims (4)

In an apparatus for manufacturing a vehicle seat provided with a skin material having a bottom plate and having a bottom base fabric,
A vacuum concave mold in which the skin material is disposed;
A presser frame that descends from above the vacuum concave mold and presses the end region of the skin material disposed in the vacuum concave mold with the opening peripheral edge of the vacuum concave mold,
Pressurizing means for pressurizing after disposing a cushion material and a bottom plate on the vacuum concave skin material;
Heating means comprising an electrothermal welder that can be moved up and down on the vacuum concave mold for heating until at least a part of the back side of the bottom plate is melted;
The presser frame and a standing wall portion provided at the peripheral edge of the vacuum concave opening are arranged at a predetermined interval so that the back base fabric of the skin material contacts the melted portion of the bottom plate, and the opening A skin material folding means for folding a terminal region of the skin material to the back surface side of the bottom plate by an extending means extending from the peripheral edge side toward the inside of the vacuum concave mold,
A vehicular seat manufacturing apparatus, comprising: a pressing means for lowering the heating means and pressing the back surface side of the bottom plate and the end region of the skin material. The vehicular seat manufacturing apparatus according to claim 1 , wherein the presser frame is configured such that the front side faces upward when the presser frame is raised . In the manufacturing method of a vehicle seat provided with a skin material having a bottom plate and having a bottom base fabric,
Arranging the skin material in a vacuum concave mold;
Lowering the presser frame from above the vacuum concave mold, pressing the terminal area of the skin material disposed in the vacuum concave mold between the opening peripheral edge of the vacuum concave mold, and
Vacuum forming the skin material;
A step of disposing and pressurizing a cushion material and a bottom plate on the vacuum-formed skin material,
Heating by heating means that can be raised and lowered on the vacuum concave mold until at least a part of the back side of the bottom plate is melted;
A step of temporarily raising the heating means after the heating step;
Folding the end region of the skin material to the back side of the bottom plate so that the back base fabric of the skin material is in contact with the melted portion of the bottom plate;
In the step of raising the heating means, the heating means is cooled and then lowered, and the bottom plate is positioned at the melted portion of the bottom plate so that the molten resin in which the bottom plate is melted penetrates. Pressurizing the end region of the skin material that has been made,
Cooling the terminal region of the skin material until the molten resin that has penetrated into the back base fabric is solidified. After the step of vacuum forming the skin material, the portion sandwiched between the press frame and the peripheral edge of the opening of the vacuum concave portion from the other portion of the terminal area of the skin material fixed by the presser frame. 4. The trimming step of separating , and the presser frame raising step in which the front of the presser frame faces upward when the presser frame is raised and raised after the trimming step . A method for manufacturing a vehicle seat.

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