JP5808963B2 - Method for producing a component comprising a foam material - Google Patents

Description

The present invention relates to a method for manufacturing a component including a foam material, including a support member, a foam material layer, and an interior cover attached to the foam material layer and sewn.
More specifically, the present invention belongs to the field of manufacturing methods for automotive foam material parts such as dashboards and interior panels for doors. The present invention relates to a foamed material part having an interior cover made of natural leather or cloth, or an interior cover suitable for sewing.

  Foam material parts for vehicles, such as certain types of dashboards, include support members made of rigid plastic material, interior covers, and foam assembled between these interior covers and rigid plastic material support members With a layer of plastic material. The manufacture of this type of part is obtained using a foaming die with a bottom die and a plunger, which in the closed position defines a foaming cavity, in which a plastic foam material, usually Injects and polymerizes pre-urethane foam.

  In most cases, the interior cover is not of the type that is sewn. When the interior cover does not require sewing, the interior cover is attached to the position adjustment surface of the bottom die of the foaming die and brought into contact with the position adjustment surface by suction. A support member of rigid plastic material is placed on the plunger and the foaming die is closed. Thereafter, a foaming material is injected into the foaming gap between the interior cover and the support member.

  In the case of certain high-grade foam material parts, the interior cover is formed by cutting and sewing an interior cover made of valuable material, for example natural leather, cloth or embroidered cover, into an elongated shape. Is done. In these cases, it is impossible to use the method used for an interior cover that is not sewn. The main problem in the case of a sewn interior cover is the precise positioning of the seam rows appearing on the surface of the foam material part (this is important for the aesthetic appearance). The method used for interior covers that do not require sewing is planned to be installed on the surface of the bottom die, ensuring the accuracy required for positioning the rows of seams in the interior cover in the final product. Can not give to.

  When it is necessary to provide an interior cover on a dashboard or other vehicle foam material parts in the prior art, the foam material parts are first manufactured without the interior cover and then sewn. An interior cover is applied to the foam material part and an additional step is added to schedule the use of the adhesive to the foam material layer of the sewn interior cover. These processes are basically of a nature that requires skill and involve high costs. Another disadvantage of the prior art is that car manufacturers are required to provide vehicles with both standard equipment with non-sewn interior covers and optional equipment with sewn interior covers made of expensive materials. Need to have two different foaming dies. Otherwise, parts with expensive interior covers will have a greater thickness than parts with interior covers that are not sewn, and will fit into the foam material parts housing given by design. It will disappear.

European Patent Application No. 0965425A2 European Patent Application Publication No. 2003089A2 German Patent Application No. 102004023582A1 US Pat. No. 4,987,666

  An object of the present invention is to provide a method for manufacturing a foamed material part having a cover for a sewn interior that can overcome the problems in the prior art.

In order to solve the above-mentioned problems, the present invention includes a support member (42), a foam material layer (50), and a foam including an interior cover (10) applied on the foam material layer (50). In the manufacturing method of the material part (48),
Forming the interior cover (10) by sewing a plurality of elongated interior cover pieces (10 ′, 10 ″, 10 ″ ′);
Installing the sewn interior cover (10) on the convex position adjustment surface (16) of the positioning member (14);
Attracting the sewn interior cover (10) onto the positioning member (14) using a first suction system (24);
Placing the positioning member (14) in a state where the sewn interior cover (10) is attracted to the upper part in the bottom die (28) of the foaming die;
Stop the first suction system (24) and use the second suction system (36) to place the interior cover (10) on the concave position adjustment surface (34) of the bottom die (28). Attracting process,
Detaching the positioning member (14) from the bottom die (28) so as to leave the interior cover (10) in a state of being attracted by suction onto the concave position adjustment surface (34);
A rigid support member (42) is placed on the plunger (40) of the foaming die, and the plunger (40) is closed on the bottom die (28) to close the support member (42). Forming a foaming gap (44) between an outer surface and the interior cover (10);
The present invention includes a step of injecting a foaming material into the foaming gap (44) and polymerizing the foaming material.

Sectional drawing which shows the process of the manufacturing method by this invention. Sectional drawing which shows the process of the manufacturing method by this invention. Sectional drawing which shows the process of the manufacturing method by this invention. Sectional drawing which shows the process of the manufacturing method by this invention. Sectional drawing which shows the process of the manufacturing method by this invention. Sectional drawing which shows the process of the manufacturing method by this invention.

  In the method according to the present invention, in the first step, the interior cover 10 is formed by cutting a plurality of elongated interior cover pieces 10 ', 10 ", 10"' and sewing them together. The elongated interior cover pieces 10 ', 10 ", 10"' can be formed from natural leather, cloth or other high quality interior cover material. The seam between the long interior cover pieces 10 ′, 10 ″, 10 ″ ′ is indicated by reference numeral 12.

As shown in FIG. 1, the sewn interior cover 10 is disposed on a positioning member 14 having a convex position adjustment surface 16. The seam of the interior cover is disposed inside a corresponding seat surface 18 formed on the convex position adjusting surface 16 of the positioning member 14. Preferably, the position adjustment surface 14 is formed from a plurality of separable sections 20. The positioning member 14 is carried by the movable support 22. The movable support 22 supports a suction system 24 having a suction duct 26 communicating with the convex position adjusting surface 16. The suction system 24 creates a negative pressure between the interior cover 10 and the convex position adjustment surface 16. This negative pressure attracts the sewn interior cover 10 to the exact position of the convex position adjustment surface 16.

  In the next step, as shown in FIG. 2, the movable support 22 is moved manually or automatically, and the positioning member 14 in a state in which the sewn interior cover 10 is attracted to the upper portion is used as the bottom of the foaming die. Arranged inside the die 28. In this embodiment, the bottom die 28 consists of a fixed part 30 and two movable parts 32 that are movable between an open position and a closed position in the direction indicated by two opposing arrows A. The bottom die 28 has a concave position adjustment surface 34 on which the interior cover 10 is to be placed. The bottom die 28 has a second suction system 36 having a duct 38 connected to a concave position adjustment surface 34.

  As shown in FIG. 3, the positioning member 14 is placed on the concave position adjustment surface 34 of the fixed portion 30 of the bottom die 28. Thereafter, the movable die 32 is closed to place the bottom die 28 in the arrangement shown in FIG. In this arrangement, the interior cover 10 is disposed on the position adjusting surface 34 having an outer surface that is concave, and the inner surface is attracted to the convex position adjusting surface 16 of the positioning member 14.

  While the positioning member 14 is inserted and attracted into the bottom die 28, the interior cover 10 is attracted to the position adjustment surface 16 by suction. When the positioning member 14 is in the position shown in FIG. 3, the first suction system 24 is stopped, and immediately thereafter, the second suction system 36 is activated. In this way, the interior cover 10 is attracted by suction so as to contact the concave position adjusting surface 34 of the bottom die 28.

  In the next step (FIG. 4), the positioning member 14 is detached from the bottom die 28, and the interior cover 10 is left in a state of being attracted by suction onto the concave position adjusting surface 34 of the bottom die 28. When the concave position adjusting surface 34 has an undercut shape as shown in the drawing, the section 20 forming the positioning member 14 is separated as shown in FIG. The movable part 32 can be removed from the die 28 without opening it.

  Next, as shown in FIG. 5, the foaming die plunger 40 holding the support member 42 made of a rigid plastic material is closed so as to be closed on the bottom die 28. In the state where the plunger 40 is disposed on the bottom die 28, a foaming gap 44 is formed between a part of the outer surface of the support member 42 and the interior cover 10. The plunger 40 is connected to an injection channel 46 that is in communication with the foaming gap 44 through one or more holes provided in the support member 42. A foamable material, such as polyurethane foam, is injected into the foaming cavity 44 through the injection channel 46. The material that can be foamed polymerizes in the foaming gap 44 and adheres firmly to the support member 42 and the interior cover 10.

In the last step (FIG. 6), the plunger 40 is lifted, the movable part 32 of the bottom die 28 is opened and the suction by the second suction system 36 is stopped.
According to the above method, the foamed material part 48 including the support member 42 made of a rigid plastic material, the sewn interior cover 10, and the foamed material layer 50 that adheres the sewn interior cover 10 to the support member 42 is obtained. can get. The interior cover 10 that has been sewn can be fixed by bonding the foam material layer 50. The sewn interior cover 10 can be placed on the foam material layer 50 with high accuracy. The overall thickness of the foam material part was almost the same whether the interior cover 10 that had been sewn was used or an interior cover that did not require sewing. According to the present invention, the same foaming die can be used both when a sewn interior cover 10 is used and when an interior cover that does not require sewing is used.

  The solution according to the invention also eliminates the additional step of adhering the sewn interior cover 10 to the foam material layer, for example the step of attaching the interior cover to the foam material layer using an adhesive. to enable.

Claims (2)

In a method for producing a foam material part (48) comprising a support member (42), a foam material layer (50), and an interior cover (10) applied on the foam material layer (50),
Forming the interior cover (10) by sewing a plurality of elongated interior cover pieces (10 ′, 10 ″, 10 ″ ′);
Installing the sewn interior cover (10) on the convex position adjustment surface (16) of the positioning member (14);
The interior cover (10) sewn on the positioning member (14) using a first suction system (24) having a suction duct (26) communicating with the convex position adjustment surface (16 ). Attracting the process,
Placing the positioning member (14) in a state where the sewn interior cover (10) is attracted to the upper part in the bottom die (28) of the foaming die;
Using the second suction system (36) having a duct (38) connected to the concave positioning surface (34) of the bottom die (28) and stopping the first suction system (24) a step of attracting the sewn interior cover (10) to a position regulation surface of the concave (34) Te,
The positioning member (14) is detached from the bottom die (28) so as to leave the sewn interior cover (10) in a state attracted by suction onto the concave position adjustment surface (34). Process,
A rigid support member (42) is placed on the plunger (40) of the foaming die, and the plunger (40) is closed on the bottom die (28) to close the support member (42). Forming a foaming gap (44) between an outer surface and the sewn interior cover (10);
Injecting a foam material into the foam gap (44), and polymerizing the foam material ;
The positioning member (14) comprises a plurality of separable compartments (20), the plurality of compartments (20) allowing the positioning member (14) to be detached from the bottom die (28). Separate from each other,
Manufacturing method of foam material part (48). The seam (12) of the sewn interior cover (10) is inserted into the corresponding seating surface (18) formed on the convex position adjusting surface (16) of the positioning member (14). The method of claim 1.