JP4888627B2 - Manufacturing method of armrest - Google Patents

Description

  The present invention relates to a method for manufacturing an armrest provided on a vehicle or furniture seat, particularly an automobile seat.

  Armrests used for automobile seats are filled with pad material made of foamed resin inside the skin material formed in a predetermined bag shape with cloth, etc., and inside the pad material is a metal frame as a skeleton member Is provided.

  When manufacturing this type of armrest, first, a metal frame is inserted into the skin material. The frame is inserted into the skin material from the foaming raw material injection port provided at the tip of the skin material.

  Then, the skin material into which the frame is inserted is set in a mold having a cavity surface corresponding to a predetermined outer surface shape. Then, after injecting the foam raw material into the inside from the injection port formed at the tip of the skin material, sealing the injection port, foaming the foam raw material, while pressing the skin material against the cavity surface by the pressure during foaming, A pad material having an outer shape corresponding to the cavity surface is formed inside the skin material (see, for example, Patent Document 1).

When attaching the cup holder container to the armrest, it is necessary to form a recess for attaching the cup holder container in advance to the pad material inside the armrest. The concave portion is formed by a convex portion formed in the mold. In addition, a box-type cup holder container housing portion corresponding to the inner surface shape of the recess is formed in advance so that the skin material is closely adhered along the inner surface of the recess at the portion corresponding to the recess in the skin material. . Therefore, the sealing material maintains the sealing property even at the portion where the cup holder container is attached, and the foaming material does not leak out of the covering material.
JP 2004-105644 A

  However, in such a conventional technique, since the frame is inserted into the skin material using the injection port of the foaming raw material, it is necessary to make the injection port large. The large inlet can easily inject the foaming material, but the foaming material may leak out. In addition, it is troublesome to close the large inlet after injecting the foaming raw material.

  The present invention has been made paying attention to such a conventional technique, and provides a method for manufacturing an armrest capable of reducing the injection port of the foaming raw material.

  According to the first aspect of the present invention, a metal frame is inserted into a skin material formed in a predetermined bag shape, and the skin material into which the frame is inserted has a cavity surface corresponding to a predetermined outer surface shape. The foam material is injected into the inside from the inlet formed in the skin material, the foam material is foamed and the skin material is pressed against the cavity surface, and a pad material having an outer surface shape corresponding to the cavity surface is formed. An opening for a cup holder container is formed at a position near the tip of the skin material, and a cylindrical folded portion is formed from the edge of the opening toward the inside of the skin material. The recessed portion for attaching the cup holder container, in which the folded portion is closely adhered to the inner surface by foam molding, can be formed in the pad material, and when the frame is inserted into the skin material, the arc at the folded portion of the opening is formed. Front end portion of the rest is inward, the base end is a state of outward, and wherein the insertion toward the opening of the frame from the front end portion.

  The invention according to claim 2 is foam-molded in a state where a nest whose bottom is held by the frame and whose side is in close contact with the folded portion is mounted in the opening, and has a shape corresponding to the nest from the opening toward the internal pad material A recess is formed, and a cup holder container can be attached in the recess.

  The invention described in claim 3 is characterized in that a magnet is provided on the bottom surface of the nest, and the nest is held in the frame by the magnet.

  According to a fourth aspect of the present invention, the armrest is supported so as to be rotatable about the base end portion, and is formed into a structure that can be obtained in a retracted state in which the tip end portion is substantially upward and a use state in which the tip end portion is directed forward. Therefore, an opening is formed at a position near the tip of the portion that becomes the upper surface in use.

  According to the first aspect of the present invention, since the frame can be inserted into the skin material from the opening for the cup holder container, the injection port for the foaming raw material can be small. Therefore, the work of closing the injection port is easy, and there is no possibility that the foaming raw material leaks from there.

  According to the invention described in claim 2, since the recess is formed by nesting and the nesting is removed after molding, it is not necessary to form the projection on the molding die, the shape of the molding die is simplified, and the molding die is manufactured. Becomes easier.

  According to the third aspect of the present invention, since the nest is held in the frame by the magnet, the nest can be easily attached and detached.

  According to invention of Claim 4, it can employ | adopt also as an armrest which can be rotated centering | focusing on a base end part.

  For the purpose of providing a manufacturing method of an armrest that can reduce the foaming raw material inlet, a metal frame is inserted into the skin material formed in a predetermined bag shape, and the skin material into which the frame is inserted is provided. It is set in a mold having a cavity surface corresponding to a predetermined outer surface shape, a foaming material is injected into the inside through an injection port formed in the skin material, the foaming material is foam-molded, and the skin material is pressed against the cavity surface. A method of manufacturing an armrest for forming a pad material having an outer surface shape corresponding to a cavity surface, wherein an opening for a cup holder container is formed at a position near the tip of the skin material, and an outer skin is formed from an edge of the opening. A concave part for attaching a cup holder container in which a folded part is formed in close contact with the inner surface by forming a cylindrical folded part toward the inside of the material and foaming can be formed in the pad material. When inserting the frame into the skin, keep the armrest tip side facing inward and the base end side facing outward, and turn the frame from the tip side into the opening. Realized by inserting. Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  1 to 26 are diagrams showing an embodiment of the present invention. First, the structure of the armrest 1 will be described with reference to FIGS. The armrest 1 of this embodiment is used by being installed on an automobile seat. The armrest 1 basically has a metal frame 3 as a skeleton member inserted into a skin material 2 formed in a predetermined bag shape, and is made of urethane foam between the skin material 2 and the frame 3. The pad material 4 is formed.

  The skin material 2 is formed of a woven fabric having low stretchability (leather may be used). In the skin material 2 on the surface of the armrest 1, two groove portions 5 are formed along the longitudinal direction as an uneven pattern. A cup holder container 6 is provided on the back surface of the armrest 1 at a position closer to the tip 1a. The cup holder container 6 is attached by fastening means (not shown) in a recess 8 formed from the opening 8 formed in the skin material 2 toward the internal pad material 4. From the edge part of the opening 8, the cylindrical folding | turning part 9 formed in the inner side of the skin material 2 is formed, and it is in the state closely_contact | adhered to the inner surface of the recessed part 8. FIG. The folded portion 9 is formed in order to reliably prevent the pad material 4 from being exposed at the edge of the opening 8. The opening 8 is merely formed with a cylindrical folded portion 9, and there is no need to provide a box-type cup holder container that completely closes the opening 8 as in the prior art.

  The frame 3 inside the pad material 4 is constructed by two frame main bodies 3a extending in the longitudinal direction, two cross members 3b connecting them, a holder support 3c on the front end 1a side, and a holder support 3c. Plate 3d, a pair of brackets 3e and 3f on the base end 1b side, a hinge pipe 3g constructed between the pair of brackets 3e and 3f, a socket 3h inserted at both ends of the hinge pipe 3g, And a case 10 fixed to the bracket 3f.

  Hinge holes 11 are formed in the skin material 2 and the pad material 4 on the side surfaces of the armrest 1 on both sides of the base end portion 1b. The socket 3 h is exposed on the bottom surface of the hinge hole 11. The hinge hole 11 is pivotally supported by a vehicle seat (not shown) so that a retracted state in which the front end portion 1a is substantially upward and a use state in which the front end portion 1a is directed forward are obtained.

  A curved slit 12 is formed around the hinge hole 11 in the skin material 2 on one side of the base end 1 b of the armrest 1. A striker 13 (see FIG. 6) as an engaging member is inserted into the curved slit 12 from the sheet side (not shown), and relatively moves along the curved slit 12 as the armrest 1 rotates.

  Inside the curved slit 12, an extension 10 a formed from the case 10 is exposed via a resin sheet 15 having the same curved slit 14. Both the case 10 and the extension 10a have an open cross-sectional structure that is open on the outside. The inside of the case 10 and the extension 10a is hollow and the pad material 4 is not formed.

  The extension 10a is for forming a movement space for the striker 13, and the case 10 is for forming a storage space for a lock mechanism 16 as a mechanism. The lock mechanism 16 engages with the striker 13 when the armrest 1 is in the retracted state, and maintains the retracted state.

  The lock mechanism 16 is provided with a release lever 17 (see FIG. 5), and a strap 18 as an operating force transmission means is connected to the release lever 17. The strap 18 protrudes from the notch 19 restricted by the skin material 2, and by pulling the strap 18, the locked state of the striker 13 by the lock mechanism 16 is released, and the armrest 1 is rotated to be used. Can be.

  Next, a method for manufacturing the armrest 1 will be described with reference to FIGS. First, the frame 3 is inserted into the skin material 2 formed in a predetermined bag shape. As shown in FIG. 11, the frame 3 is inserted into the skin material 2 using the opening 8 for the cup holder container 6. Conventionally, the frame 3 is inserted from the injection port 20 formed in the base end portion 1b of the skin material 2. However, in this embodiment, the injection port 20 is used only for injection of the foaming material. The size of 20 can be small.

  A cylindrical folded portion 9 is formed in the opening 8 of the skin material 2, but the end portion on the base end portion 1b side faces outward, and the end portion on the distal end portion 1a side remains inward. By doing so, the frame 3 can be reliably inserted into the skin material 2 without interfering with the folded portion 9. Further, since the opening 8 is formed at a position closer to the distal end portion 1 a, the entire frame 3 can be inserted into the skin material 2 from the opening 8. After inserting the frame 3, the folding part 9 is returned to its original state.

  Next, the insert 21 having a shape corresponding to the cup holder container 6 is inserted into the opening 8. A magnet 22 is provided on the bottom surface of the insert 21, and a stronger magnet 24 is provided on the handle portion 23 of the insert 21. In addition, two protrusions 25 are formed on the bottom surface of the insert 21. The protrusions 25 are formed at asymmetric positions in the longitudinal direction and the width direction of the armrest 1.

  Through holes 26 corresponding to the three protrusions 25 are formed in the plate 3d. The bottom surface of the insert 21 is brought into contact with the plate 3d, and the three protrusions 25 are passed through the through holes 26. The protrusion 25 is longer than the thickness of the plate 3d and protrudes from the plate 3d to the inside of the skin material 2.

  By placing the insert 21 on the plate 3d, the insert 21 is held against the plate 3d by the action of the magnet 22. Further, by allowing the protrusions 25 that are asymmetric in the longitudinal direction and the width direction to pass through the through holes 26, the insert 21 can be mounted in the opening 8 in the correct orientation. The shapes of the insert 21 and the cup holder container 6 are slightly different in the longitudinal direction and the width direction. The folded portion 9 formed from the opening 8 is brought into close contact with the side surface of the insert 21 mounted in the correct orientation.

  After mounting the insert 21, the resin sheet 15 having the curved slit 14 is set on the back side of the skin material 2 and matched with the curved slit 12 of the skin material 2. The resin sheet 15 itself is bonded to a part of the case 10. As shown in FIG. 9, the curved slit 14 of the resin sheet 15 is provided with a thin and easily broken bridging portion 27. Therefore, the shape retaining property of the resin sheet 15 is maintained, and the curved slit 14 does not open when the resin sheet 15 is handled, and the handling is easy.

  Further, a top member 28 (FIGS. 16 and 17) is inserted into the hinge hole 11 portion of the skin material 2 from the outside, and the tip is engaged with the socket 3h for mounting. The top member 28 is made of metal, and a knurled surface 28a is formed on the base end side of the cylindrical side surface.

  As shown in FIG. 12, the skin material 2 and the frame 3 on which the insert 21, the resin sheet 15, and the piece member 28 are mounted are set in a vertical mold 29 with the base end 1b facing up. . The mold 29 is basically formed from a fixed mold 30 and a movable mold 31. A cavity surface 32 for shaping the groove 5 of the skin material 2 is formed in the fixed mold 30. The fixed mold 30 has a hollow structure, and the internal air can be exhausted from the exhaust port 33 using a blower (not shown). Two protrusions 34 for forming the groove 5 are formed on the cavity surface 32 along the vertical direction. A plurality of suction holes 35 are formed along the protrusion 34 at positions adjacent to both sides of the protrusion 34.

  The upper end 31a of the movable mold 31 can be partially opened. One side wall portion of the fixed mold 30 can be moved inward and outward by a drive mechanism (not shown) as the movable mold 36. The movable die 36 is also formed with a protruding pin 37. A window portion 38 (see FIG. 14) for exposing the injection port 20 is also formed on the upper portion of the fixed mold 30.

  The skin material 2 and the frame 3 are first set on the fixed mold 30 (see FIG. 18). Next, the movable die 36 is moved inward to press one piece member 28. By doing so, the pair of top members 28 and the hinge pipe 3g are sandwiched between the side wall portion of the fixed mold 30 and the movable mold 36, and the frame 3 is held in the fixed mold 30. (See FIG. 19). In this state, since the protruding pin 37 protrudes and further presses the top member 28, the holding state of the frame 3 is further ensured.

  At this time, the edge of the hinge hole 11 of the skin material 2 is in contact with the knurled surface 28 a of the top member 28. Further, the skin material 2 is pressed against the end of the extension 10 a of the case 10 by the movable die 36 with the resin sheet 15 interposed. Also, the skin material 2 is pressed against the terminal of the case 10 by the movable die 36 (see FIG. 22). A release hole 39 is formed in the movable die 36, from which the strap 18 can be taken out.

  After the movable mold 36 is tightened, the movable mold 31 is also tightened to bring the molding die 29 into a complete mold clamping state (see FIG. 13). In this state, the skin material 2 is sucked from the suction hole 35 so that the skin material 2 is brought into close contact with the cavity surface 32 (particularly the protrusion 34).

  Then, the foaming material is injected from the upper nozzle 40 into the skin material 2 through the injection port 20. After injection of the foam material, the injection port 20 is sealed and closed. After closing the injection port 20, the foaming raw material is foam-molded in the molding die 29. By doing so, the skin material 2 other than the portion sucked and brought into close contact with the cavity surface 32 is also pressed against the inner surface of the mold 29 by the foaming pressure.

  At the time of foam molding, since the edge of the hinge hole 11 is in contact with the knurled surface 28a of the top member 28, the foaming raw material does not leak from there. Further, also in the case 10 and the extension portion 10a, the skin material 2 is pressed by the movable die 36 directly or via the resin sheet 15 to the terminal, so that the foaming raw material enters the case 10 and the extension portion 10a. There is nothing.

  After foam molding, the movable mold 31 and the movable mold 36 are opened, and the molded armrest 1 is taken out. When the movable mold 31 is opened, the insert 21 is automatically detached from the opening 8 while being magnetically attached to the movable mold 31 by the action of the strong magnet 24 of the handle portion 23 (see FIG. 24).

  After the insert 21 is removed, the concave portion 8 having a shape corresponding to the insert 21 is formed. An insertion hole 41 corresponding to the protrusion 25 of the insert 21 is formed at the bottom of the recess 8. The folded portion 9 is in close contact with the inner surface of the recess 8.

  The two top members 28 are also removed together with the insert 21. After removing the top member 28, the hinge hole 11 is formed.

  A resin sheet 15 having a similar curved slit 14 is provided inside the curved slit 12 in a polymerized state, and the rigidity of the curved slit 12 is increased. The bridging portion 27 formed in the curved slit 14 of the resin sheet 15 is removed by breaking after molding. Since the bridging portion 27 is easy to break, the bridging portion 27 may be used as it is without being broken, and may be naturally removed by the sheet-side striker 13 inserted into the curved slit 12.

  Finally, when the cup holder container 6 is put into the recess 8 and attached, the armrest 1 is completed. When the cup holder container 6 is attached, if the orientation of the cup holder container 6 is not correct, the projection 42 on the bottom surface and the insertion hole 41 do not match and cannot be attached, so that erroneous attachment is prevented.

  The main functions and effects of this embodiment are listed below.

  According to this embodiment, since the frame 3 can be inserted into the skin material 2 from the opening 8 for the cup holder container 6, the injection port 20 for the foaming material can be small. Therefore, the operation | work which plugs the injection inlet 20 is also easy, and there is no possibility that a foaming raw material may leak from there.

  Next, incidental actions and effects of this embodiment will be listed.

  According to this embodiment, the foam material is sucked from the suction holes 35 before being injected, and the skin material 2 is adsorbed to the cavity surface 32. The uneven pattern corresponding to the shape of the surface 32 can be formed reliably. Accordingly, the degree of freedom in selecting the skin material 2 used for the armrest 1 is improved.

  Since the suction holes 35 are formed at positions close to both sides of the ridge 34, the suction action by the suction holes 35 can be concentrated on the ridge 34, and even if the groove portion 5 has a certain depth due to the ridge 34, it is reliably formed. can do.

  Since the skin material 2 and the frame 3 can be held in the molding die 29 through the piece member 28 inserted from the outside, an overhanging portion having a length reaching the cavity surface 32 of the molding die 29 is formed on the frame 3. Therefore, the structure of the frame 3 is simplified. Moreover, since the top member 28 is removed after molding, the weight of the frame 3 can be reduced.

  Since the knurled surface 28 a is formed at the portion of the top member 28 that contacts the skin material 2, leakage of the foaming raw material from the contact portion between the top member 28 and the skin material 2 can be prevented.

  Since the top member 28 is pressed by the movable die 36 of the molding die 29, the frame 3 is securely held in the molding die 29.

  Since the top member 28 is pressed by the projecting pins 37 provided on the movable die 36, the frame 3 is more reliably held in the molding die 29.

  According to this embodiment, since only the opening 8 having the cylindrical folded portion 9 is formed in the skin material 2 and there is no need to form a conventional cup holder container housing portion, the production of the skin material 2 is possible. Is easy. Further, since the concave portion 8 is formed by the insert 21 and the insert 21 is removed after molding, it is not necessary to form the convex portion on the mold 29, the shape of the mold 29 is simplified, and the mold 29 can be easily manufactured. become.

  Since the insert 21 is held on the frame 3 by the magnet 22, the insert 21 can be easily attached and detached.

  It is possible to prevent erroneous mounting and erroneous mounting of the insert 21 and the cup holder container 6.

  Since the handle portion 23 is provided in the insert 21, the insert 21 can be easily handled. Since the magnet 24 provided on the handle portion 23 is stronger than the magnet 22 on the bottom surface, when the movable mold 31 is opened, the insert 21 is removed together with the movable mold 31 while being magnetically attached to the movable mold 31. be able to.

  According to this embodiment, even in the case 10 having an open cross-sectional structure, the skin material 2 is pressed against the terminal of the case 10 by the movable die 36, so that the foaming raw material does not enter the case 10. Since the case 10 has an open cross-sectional structure, the case 10 can be easily manufactured, and the lock mechanism 16 can be easily stored in the case 10. Moreover, the strap 18 for operating the lock mechanism 16 can also be directly taken out through the skin material 2. Therefore, it is not necessary to secure the path of the strap 18 using a tube as in the prior art, and the structure is simplified.

  Since the release hole 39 for letting the strap 18 out is formed in the movable mold 36, the strap 18 and the movable mold 36 do not interfere with each other, and the pressing operation of the case 10 by the movable mold 36 can be performed reliably.

  Since the skin material 2 is also pressed by the movable die 36 through the resin sheet 15 to the end of the extension portion 10a corresponding to the curved slit 12, it is possible to prevent the foaming raw material from entering the extension portion 10a. Since the resin sheet 15 is interposed, the sealing performance between the end of the extension portion 10a and the skin material 2 is improved, and the rigidity of the peripheral portion of the curved slit 12 is improved.

  Since the bridging portion 27 is formed in the curved slit 14 of the resin sheet 15, the shape retention of the resin sheet 15 itself is improved and the handling of the resin sheet 15 is facilitated. Since the bridging portion 27 is easy to break, it can be broken after molding to form the original continuous curved slit 14.

  In the above embodiment, the armrest 1 provided on the seat of the automobile is taken as an example. However, the present invention is not limited to this. The seat is used for other vehicles such as trains, airplanes, ships, etc., or the seat for furniture. Is also applicable.

The perspective view which looked at the armrest which concerns on the Example of this invention from the surface side. The perspective view which looked at the armrest of FIG. 1 from the back surface side. Sectional drawing which shows the armrest of FIGS. Sectional drawing of the armrest which follows the arrow SA-SA line in FIG. Sectional drawing of the armrest which follows the arrow SB-SB line in FIG. Sectional drawing of the armrest which follows the arrow SC-SC line in FIG. The side view of the armrest seen from the arrow DA direction in FIG. The figure which shows the state which removed the bridge | crosslinking part of the resin sheet of FIG. The figure which shows the state before removing the bridge | crosslinking part of the resin sheet of FIG. The top view of the cup holder container part seen from the arrow DB direction in FIG. Sectional drawing which shows the state which inserts a flame | frame inside the armrest skin material of FIG. Sectional drawing which shows the state which sets the skin material and flame | frame of FIG. 11 to a shaping | molding die. Sectional drawing which shows the state which clamped the shaping | molding die of FIG. The top view of the shaping | molding die seen from the arrow DC direction in FIG. Sectional drawing which shows the shaping | molding die of FIG. FIG. 16 is a cross-sectional view of the molding die showing a state in which the skin material and the frame are set on the molding die after the top member of FIG. 15 is mounted. The perspective view which shows the top member of FIG. Sectional drawing which shows the state which sets a skin material and a flame | frame to the shaping | molding die of FIG. Sectional drawing of the shaping | molding die which shows the state which pressed the top member and the extension part with the movable type | mold of FIG. FIG. 20 is a cross-sectional view of a molding die showing a state in which the movable die in FIG. 19 is clamped and the skin material is sucked. FIG. 21 is a cross-sectional view corresponding to FIG. 20 showing a state where the foaming material of FIG. Sectional drawing of the shaping | molding die which shows the case part of FIG. Sectional drawing of the shaping | molding die which shows the nesting part in FIG. FIG. 24 is a cross-sectional view of a forming die showing a state where the movable die of FIG. 23 is opened together with the insert. The perspective view which shows the nest | insert and plate in FIG.23 and FIG.24. The perspective view which shows the cup holder container of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Armrest 1a Tip part 1b Base end part 2 Skin material 3 Frame 4 Pad material 5 Groove part 6 Cup holder container 7 Opening 8 Recessed part 9 Folding part 10 Case 10a Extension part 11 Hinge hole 12 Curved slit 13 Strike (engaging member)
15 Resin sheet 16 Lock mechanism (mechanism)
18 Strap (operating force transmission means)
20 Inlet 21 Nested 22, 24 Magnet 25 Projection (Nested)
26 Through-hole 27 Bridging portion 28 Top member 28a Knurling surface 29 Mold 30 Fixed die 31 Movable die 32 Cavity surface 34 Projection 35 Suction hole 36 Moving die 37 Projection pin 39 Release hole 41 Insertion hole 42 Protrusion (cup holder container)

Claims (4)

A metal frame is inserted into the skin material formed in a predetermined bag shape, and the skin material into which the frame is inserted is set in a mold having a cavity surface corresponding to the predetermined outer surface shape, and formed into the skin material. A foam raw material is injected into the inside from the injection port, the foam raw material is foam-molded, and a skin material is pressed against the cavity surface to form a pad material having an outer surface shape corresponding to the cavity surface. ,
An opening for the cup holder container is formed at a position near the tip of the skin material, a cylindrical folded portion is formed from the edge of the opening toward the inside of the skin material, and the folded portion is formed by foam molding. A recess for attaching the cup holder container that is in close contact with the inner surface can be formed in the pad material,
When inserting the frame into the skin, keep the armrest tip side facing inward and the base end side facing outward, and turn the frame from the tip side into the opening. A method for manufacturing an armrest, wherein the armrest is inserted. It is a manufacturing method of the armrest according to claim 1,
Foam molding is carried out with the insert held in the opening with the bottom face held by the frame and the side face in close contact with the folded portion, and a recess having a shape corresponding to the insert is formed from the opening portion toward the internal pad material. A method of manufacturing an armrest, characterized in that a cup holder container can be attached inside. It is a manufacturing method of the armrest according to claim 2,
A method for manufacturing an armrest, wherein a magnet is provided on a bottom surface of the nest, and the nest is held by the magnet by the magnet. It is a manufacturing method of an armrest given in any 1 paragraph of Claims 1-3,
The armrest is pivotally supported around the base end, and is molded into a structure that provides a retracted state with the tip end facing substantially upward and a use state with the tip end facing forward. A method of manufacturing an armrest, wherein an opening is formed at a position near the tip of the portion to be.

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