JP4261157B2 - Cushion pad with skin and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a cushion pad with an outer skin comprising an elastic resin foam and an outer skin that covers and covers at least a part of the surface, and a method for producing the same. In particular, the present invention relates to a cushion pad used as a seat cushion, an armrest or the like in a seat portion or office chair of an automobile or other vehicle.
[0002]
[Prior art]
As a seat cushion used for a seating portion and a backrest portion of an automobile seat, a combination of an elastic resin foam such as a flexible urethane foam and a skin covering such as a cloth or leather is used. An automobile seat cushion is attached to a seat frame, and such a seat portion is attached to a vehicle body via an adjuster.
[0003]
In addition to fabrics and knitted fabrics, the cushion pad's skin is made of leather such as PVC leather or synthetic leather (narrow sense) (a plastic sheet covered with a cloth), natural leather, artificial leather, and these resin laminates. The body is used.
[0004]
In manufacturing the seat cushion, in order to assemble the skin on the surface of the pad-like elastic resin foam, wire is embedded in each of the resin foam and the skin, and these are used as ring-shaped locking devices, etc. The method of locking them together is more widely performed than before. However, such an assembling method requires a large number of assembly man-hours, resulting in high costs.
[0005]
This will be described using an example shown in FIG. In order to create a joint for assembly, when the cushioning resin foam 5 is created by foam molding, a wire 57 is embedded at a predetermined location by insert molding. In addition, the skin 4 is folded in the shape of a bay into the back side at a location corresponding to this, and the wire 47 is stored, and the inside of the bay is sewn with a thread 46. And these wires 47 and 57 are fastened for every predetermined space | interval with the ring-shaped metal fitting called the hog ring 7, for example. Thus, it is necessary to perform many process operations.
[0006]
In order to simplify the process of assembling the skin, a method using an adhesive is also performed.
[0007]
However, even in the method of assembling with an adhesive, it is necessary to go through various steps such as application of the adhesive, pressing with a mold or the like, completion of curing by heating, and subsequent cooling. For this reason, the number of man-hours for assembly cannot be reduced so much (JP-A-6-39925).
[0008]
In addition, since the cured adhesive layer is formed on the back surface of the epidermis, there is a problem that the flexibility is impaired and the sitting comfort is deteriorated.
[0009]
Therefore, a method has been studied in which an elastic resin foam is manufactured by setting the skin in advance on the inner surface of the mold by suction adsorption or the like so that the skin is integrally bonded simultaneously with foam molding.
[0010]
However, it took a considerable amount of work to make the skin adhere evenly and uniformly to the inner surface of the mold. Further, there is a problem that it is difficult to sufficiently prevent the skin from locally rising from the inner surface of the mold or from locally loosening and wrinkling.
[0011]
Further, when the skin is porous, such as cloth, the resin liquid is impregnated into the skin during foam molding, creating a high-density and rigid portion, and the surface feel and elasticity are impaired. In some cases, the reactive resin liquid may protrude from the outer surface of the skin from the seam of the skin.
[0012]
In order to prevent wrinkles, there has been proposed a method for improving the method of fixing and sticking the epidermis (JP-A-5-162151). However, this method also requires a large number of work steps for wrinkle stretching, and depending on the material of the skin, it may be difficult to achieve sufficient adhesion. Moreover, it cannot cope with the problem of resin penetration when the skin is a fabric or the like.
[0013]
In addition, a method has been proposed in which a relatively hard resin film is locally formed by spraying a reactive resin liquid on the surface where wrinkles are likely to occur on the skin held on the inner surface of the mold (special feature). Kaihei 6-320551). However, in this method, the touch and elasticity may be impaired due to the formation of a relatively hard resin film.
[0014]
On the other hand, a method of forming a skin by applying a reactive resin solution such as a polyurethane resin stock solution to the inner surface of a mold has also been proposed (Japanese Patent Laid-Open No. 7-108540). However, this method is not only limited in the type of skin obtained, but also requires coating and curing operations to form the skin, leading to an increase in cost, such as a reduction in manufacturing efficiency using a foaming mold.
[0015]
[Patent Document 1]
Japanese Patent Laid-Open No. 6-39925
[Patent Document 2]
JP-A-5-162151 [0017]
[Patent Document 3]
Japanese Patent Laid-Open No. 6-320551
[Patent Document 4]
Japanese Patent Laid-Open No. 7-108540
[Problems to be solved by the invention]
The present invention has been made in view of the above problems, and in the cushion pad with an outer skin and the manufacturing method thereof, the man-hour and cost for assembling the outer skin to the resin foam can be reduced, and the sitting comfort or tactile sensation can be reduced. Try to provide something that can be kept good.
[0020]
[Means for Solving the Problems]
The cushion pad with a skin of the present invention comprises an elastic resin foam and a skin covering the surface, and in the cushion pad with a skin provided with a joint for assembling them together, the elastic resin foam is locally The joining portion is formed by being integrally formed with the back surface of the skin.
[0021]
With the cushion pad having the above-described configuration, the man-hour and cost for assembling the outer skin to the resin foam can be reduced, and the sitting comfort or tactile sensation can be kept good.
[0022]
Preferably, a portion where the epidermis has entered the inside is locally insert-molded in the elastic resin foam. With such a configuration, since reliable joining can be performed within a relatively small area, it is possible to further satisfactorily maintain sitting comfort or tactile sensation while sufficiently fixing the skin.
[0023]
In particular, a design pattern can be provided by the bay portion.
[0024]
The method for producing a cushion pad with a skin according to the present invention is a method of producing an elastic resin foam by performing foam molding in a mold, and a method for producing a cushion pad with a skin by assembling the skin into the elastic resin foam. In the foam molding cavity of the mold, by performing foam molding in a state where the back surface of the skin is locally exposed, the elastic resin foam is locally integrated with the back surface of the skin. It is characterized by making it.
[0025]
Preferably, the skin is held by the first and second mold parts, and is used for foam molding formed by the second mold and the third mold through the opening of the second mold. The back surface of the skin is locally exposed into the cavity, and foam molding is performed in this state.
[0026]
With such a configuration, it is easy to position and fix the epidermis. In addition, since the part where the local integral molding is performed can be surely sealed by a part of the skin, it is possible to reliably prevent the elastic resin foam from expanding and leaking.
[0027]
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the present invention will be described with reference to FIGS.
[0028]
The vertical cross-sectional perspective views of FIGS. 1 and 2 schematically illustrate a mold 81 including a lower mold 1, a middle mold 2 and an upper mold 3 in an open state. Show. In particular, FIG. 1 shows a state in which the skin 4 is set on the inner surface of the lower mold 1. Moreover, the cross-sectional perspective views and cross-sectional views corresponding to FIGS. 3 to 5 schematically show the steps of manufacturing the cushion pad with the skin after the state of FIG.
[0029]
As shown in FIG. 2, the inner surface of the lower mold 1 is provided with ridge line-shaped protrusions 11 at predetermined positions. For this reason, as shown in FIG. 1, when the skin 4 is set on the lower mold 1 so that the back surface faces upward, the skin 4 rises in a ridgeline correspondingly at the ridgeline projection 11. It becomes.
[0030]
As shown in FIGS. 1 and 2, the middle mold 2 includes a four-round frame portion 25 and a thin curved surface forming portion 26 on the inner side, and the curved surface forming portion 26 has protrusions of the lower mold 1. The slit-shaped opening 21 corresponding to 11 is provided. In the illustrated example, the width of the slit-shaped opening 21 is slightly larger than the width of the root portion of the ridge-line-shaped protrusion 11 of the lower mold 1. The curved surface forming part 26 of the middle mold 2 is a curved plate shaped along the inner surface of the lower mold 1 and has a substantially uniform thickness throughout.
[0031]
As shown in FIG. 3, when the middle mold 2 is closed with respect to the lower mold 1, only a narrow gap suitable for positioning and holding the skin 4 is formed between the lower mold 1 and the middle mold 2. The As shown in FIG. 4, when the upper mold 3 is also closed, a cavity 83 for foam molding the urethane resin foam 5 is formed between the curved surface forming portion 26 of the middle mold 2 and the curved surface of the upper mold 3. It is formed.
[0032]
As shown in FIGS. 3 to 4, the portion where the skin 4 rises along the protrusion 11 of the lower mold 1 forms a bay portion 41 that enters the cavity 83 through the opening 21 of the middle mold 2. And if foam molding is performed in the cavity 83, the urethane resin foam 5 of the shape by which this baying part 41 was insert-molded is formed.
[0033]
6 to 8 schematically show the obtained cushion pad 82 with an epidermis. In the illustrated example, the cushion pad 82 with an outer skin forms a seating portion of a passenger car seat, and as shown in the plan view of FIG. 8, has a substantially rectangular shape that is long in the front-rear direction. It is slender in the direction.
[0034]
As shown in the cross-sectional view of the main part in FIG. 7 and the plan view in FIG. 8, the cut-in part 41 of the skin is a region 51 having a width corresponding to the opening 21 of the middle mold 2 and is insert-molded into the urethane resin foam 5. ing. That is, the back surface of the skin 4 that forms the skin and the surface of the urethane resin foam 5 are integrally formed in a region where the back surface of the skin 4 is exposed to the cavity 83 for foam molding through the opening 21 of the middle mold 2. It is joined.
[0035]
In the example illustrated in FIG. 8 and the like, the bay portion 41 and the insert molding region 51 draw a single smooth arc that is curved so as to protrude rearward of the cushion pad 82 with the skin when viewed in a plan view. Such an arc-shaped insert molding region 51, that is, a joint portion is formed by fixing the outer skin 4 to the urethane resin foam 5 below the occupant's buttocks and generating a rubbing sound when subjected to vibration during traveling or urethane. The wear of the resin foam 5 is prevented.
[0036]
Moreover, even if the width dimension in a top view is narrow by embedding in the urethane-resin foam 5 by moderate depth, the baying part 41 fully fixes the skin 4. At the same time, the bay entrance 41 has a design pattern on the passenger car seat.
[0037]
Hereinafter, the manufacturing process of the cushion pad 82 with the skin will be described in order.
[0038]
(1) In the mold 81 shown in FIG. 2, the space between the lower mold 1 and the middle mold 2 is opened. In the illustrated example, the mold 81 is opened and closed as the middle mold 2 and the upper mold 3 rotate with respect to the lower mold 1 around the hinge portion at the right end of the mold 81.
[0039]
(2) As shown in FIG. 1, the skin 4 is disposed at a predetermined position along the inner surface of the lower mold 1. At this time, the edge of the four circumferences of the skin 4 or the baying part 41 of the skin 4 should just be in a predetermined position, and it is not necessary to adhere the skin 4 to the inner surface of the mold.
[0040]
(3) As shown in FIG. 3, the space between the lower mold 1 and the middle mold 2 is closed, and the skin 4 is held in a positioned state.
[0041]
(4) Subsequently, the urethane resin stock solution is discharged from the foamed resin nozzle 6 and injected into the curved surface forming portion 26 of the middle mold 2 by a predetermined amount. Then, the upper mold 3 is closed so as to overlap the middle mold 2. The upper opening edge 22 of the middle mold 2 has a tapered surface and is fitted so as to be in close contact with the corresponding tapered surface 32 of the upper mold.
[0042]
(5) In this state, foam molding is performed in the cavity 83. At this time, as shown in FIG. 4, the baying part 41 of the skin 4 is insert-molded. In addition, the other part of the skin 4 is also subjected to appropriate heating and pressing, so that a kind of heat setting is performed, and has a curved shape along the outer surface of the urethane resin foam 5. For example, if the curved surface forming part 26 of the middle mold 2 is sufficiently thin, the skin 4 is clamped by the internal pressure by foam molding.
[0043]
(6) After completion of the heat curing, as shown in FIG. 5, the space between the lower mold 1 and the middle mold 2 and between the middle mold 2 and the upper mold 3 are all opened.
[0044]
(7) Then, the urethane resin foam 5 is pulled away from the inner surface of the middle mold 2, and the skin 4 locally joined thereto is gradually pulled out through the opening 21 of the middle mold 2. FIG. 6 shows a product state in which the product is turned upside down after being pulled out.
[0045]
In the manufacturing method of the above embodiment, wrinkles are not generated, and it is not necessary to keep the skin in close contact with the inner surface of the mold. Moreover, since the joining of the skin and the elastic foam is performed simultaneously with the foam molding, there is no need to perform a separate joining operation. It is also possible to heat set the skin such as leather to a predetermined shape simultaneously with foam molding. Therefore, compared with the conventional joining method, a man-hour and cost can be reduced significantly.
[0046]
In addition, since the skin and the foamable resin liquid are locally in contact with each other only through the opening 21 of the middle mold 2, even when the foamable resin liquid penetrates into the material of the skin, the width of the bonding region is sufficiently large. By taking it small, it is possible to maintain good sitting comfort and tactile sensation.
[0047]
In particular, the joints are formed by insert molding the inside of the epidermis, so that the impact on sitting comfort and tactile sensation is minimized while securing a sufficiently strong area in a narrow area. Can do. In addition, since the bay entrance has a design pattern, man-hours and costs can be further reduced as compared to the case of performing an operation for applying another pattern.
[0048]
In the above embodiment, it has been described that the protrusion 11 is provided on the lower mold 1 corresponding to the opening 21 of the middle mold 2. However, in some cases, the protrusion 11 is omitted, and a joining portion is simply formed in a planar shape. It may be.
[0049]
In the above embodiment, only one opening 21 of the middle mold 2 is provided in a slit shape. However, a plurality of slit-like openings or a plurality of dot-like openings can be provided. Shaped openings can also be combined. In this case, the middle mold 2 can be divided into two splits that open to the left and right, or a four-split split that separates left and right and back and forth.
[0050]
In the above embodiment, while the skin is held between the lower mold and the middle mold, it has been explained that the back surface of the skin is locally exposed into the foam molding cavity formed by the middle mold and the upper mold. Depending on the case, similar results can be obtained by other appropriate means. For example, instead of using the middle mold, a silicon sheet having an opening or a fluororesin sheet may be used to cover the back surface of the skin, and in this state, the skin may be set in a mold for foam molding. Further, in some cases, it is also possible to sandwich the fold-in folded portion of the skin into the gap between the two mold parts that open to the left and right, and to expose the foam molding cavity.
[0051]
In the above-described embodiments, the foam molding is described as being performed together with a reaction such as a urethane polymerization reaction. However, non-polymerization reactive foam molding in which polyethylene is foamed with an appropriate foaming agent may be used. Note that the elastic resin foam is not limited to soft and may be semi-rigid.
[0052]
In the above embodiment, the skin is not limited to fabric or knitted fabric, but may be leather, natural leather, artificial leather, plastic sheet, resin laminated sheet, or the like. Moreover, although the cushion pad with the skin has been described as being used for a seating part of an automobile seat, it may be used for a backrest part, an armrest, a headrest, a footrest, etc. It may be a pillow.
[0053]
【The invention's effect】
The man-hour and cost for assembling the skin to the resin foam can be reduced, and the sitting comfort or tactile sensation can be kept good.
[Brief description of the drawings]
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a vertical sectional perspective view showing a mold used in a manufacturing method of an embodiment in a state in which a middle mold and an upper mold are opened apart from a lower mold and a skin is set on a lower mold.
FIG. 2 is a vertical sectional perspective view similar to FIG. 1, showing the mold used in the manufacturing method of the embodiment in a state before the skin is set.
FIG. 3 is a cross-sectional perspective view corresponding to FIG. 1 showing a state in which a foamable resin liquid is discharged to the inner surface of the middle mold in a state where the skin is held between the lower mold and the middle mold.
4 is a vertical cross-sectional view corresponding to FIG. 1 showing a state in which the middle mold and the upper mold are closed and an elastic resin foam is formed in a cavity formed by these. FIG.
FIG. 5 is a cross-sectional perspective view corresponding to FIG. 1, showing a state in which a cushion pad with a skin is taken out from a mold after foam molding.
FIG. 6 is a similar vertical sectional view showing the cushion pad with the skin taken out from the mold, with the skin facing up.
FIG. 7 is a schematic vertical sectional view showing an enlargement of a joining region between the skin and the elastic resin foam.
FIG. 8 is a plan view of a cushion pad with an outer skin taken out from a mold.
FIG. 9 is a vertical sectional view showing a conventional joining method.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Lower mold | type 2 which has the processus | protrusion 11 in the inner surface 3 Upper mold | type 3 which has the opening 12 Upper mold | type 4 Skin 41 The baying part 5 of the skin 4 by the protrusion 11 Urethane resin foam 51 The baying part 41 was insert-molded in the urethane resin foam 5 region

Claims (3)

In the method of producing an elastic resin foam by performing foam molding in a mold, and producing a cushion pad with an outer skin by assembling the outer skin to the elastic resin foam,
The elastic resin foam is locally integrated with the back surface of the skin by performing foam molding in a state where the back surface of the skin is locally exposed into the cavity for foam molding of the mold. A method for producing a cushion pad with an epidermis, characterized in that The skin is held by the first and second mold parts, and into the foam molding cavity formed by the second mold and the third mold through the opening of the second mold. and locally exposing the back surface of the skin, the manufacturing method of the epidermis cushioned pad of claim 1, wherein the performing foam molding in this state. A protrusion is locally formed on the inner surface of the first mold, and an opening of the second mold is provided at a position corresponding to the protrusion, whereby the skin is formed during the foam molding. 3. The method for manufacturing a cushion pad with an outer skin according to claim 2 , wherein an inward bay portion corresponding to the protrusion is insert-molded in the elastic resin foam.

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