JP6234238B2 - Bag-like skin integrated foam molded product and method for producing the same - Google Patents

Description

  The present invention relates to a bag-like skin-integrated foam molded product such as a headrest or an armrest, and a method for manufacturing the same.

In headrests of automobiles, etc., a flat cylindrical part that extends from the bottom to the inside of the skin is provided on the bag-shaped skin, and urethane foam material is injected from the cylindrical mouth (inlet), and the foam is integrated with the bag-shaped skin. A bag-shaped skin integral foam-molded product obtained by foam molding is known. By foam molding, the foaming raw material rises and the injection port of the flat cylindrical portion can be self-sealed. Even so, the injection port is not stable, and appearance defects may occur.
Several inventions have been proposed to improve such a situation (for example, Patent Documents 1 and 2).

JP-A-9-95198 Japanese Patent Laid-Open No. 10-14707

However, as described in the claims, Patent Document 1 discloses that “... a pair of horizontal elastics whose inner peripheral edge is located at the bent portions (5a) and (5a) on the inner surface of the bottom portion of the bag-shaped skin material (2). The vehicle headrest is characterized in that the plates (6) and (6) are bonded and integrated. ”A separate horizontal elastic plate must be prepared, resulting in increased costs and inventory due to an increase in the number of parts. The management burden was imposed.
Patent Document 2 describes, as described in the claims, “... a sewing thread is sewed once along the end of the injection port in a state where the end of the injection port is opened,… the end is pulled outward, A skin material-integrated foam headrest, in which the pad material is integrally foam-molded with tension applied to the end of the inlet, and requires a tension device that pulls the end outward. In addition, the production of the headrest requires a tensioning process, which reduces productivity.

Recently, it has also been studied to soften only the epidermis portion on which the passenger's head hits in order to improve cushioning and comfort. In such a case, the bent portions (5a) and (5a) of Patent Document 1 and the end portions (15a) and (15b) of Patent Document 2 are not the same, and it becomes difficult to suppress poor appearance.
For example, as shown in FIG. 10 (a), the bottom surface of the headrest is composed of a vehicle front side skin piece S1 that is soft at the location where the passenger's head hits and a vehicle rear side skin piece S2 made of a material having a higher elasticity than this. It is assumed that a cylindrical portion T composed of tongue pieces P, P (folded portion, end portion) that goes from the portion into the bag-like epidermis is formed. Then, there is a problem that the vehicle rear side skin piece S2 that is superior in resilience overcomes and the tongue piece P falls to the vehicle front side. Even in the stage of setting the bag-shaped skin S to the foaming mold 9 (FIG. 12), the vehicle rear side skin piece S2 that overcomes the above-described elasticity is overcome, and the cylindrical portion T falls to the vehicle front side. When the headrest is foamed as shown in FIG. 10 (b), a step D is generated around the tube opening T1, or a wrinkle W or a warp Y is caused on the design surface.
As shown in FIG. 11 (a), if the front skin piece S1 and the rear skin piece S2 forming the tongue pieces P1, P2 are both soft and weak urethane slabs, the tongue piece from the bottom surface of the headrest is used. Steadily heads into the bag-like epidermis, but when the elastic force of the material of the tongue pieces P1, P2 becomes strong, deformation occurs around the tube opening T1 as shown in FIG. Have similar problems. Since the tongue pieces P1 and P2 of the front skin piece S1 and the rear skin piece S2 do not enter the inside of the skin, the bag-like skin S is left in the vertical direction, and the wrinkles are left over the exact size of the foaming mold 9. W can do. Further, when the skin piece S2 is not bent and the tongue piece P falls down as shown in FIGS. 10 (a) and 12, not only the dent of the step D having the height difference H but also the bottom and the cylindrical portion T are formed. Overlapping increases the thickness of the region, causing a problem that Y is generated.

  The present invention solves the above problem, does not increase the number of parts, does not reduce productivity without a jig device, and the elasticity of the two skin pieces forming the tongue pieces is different. It is an object of the present invention to provide a bag-like skin-integrated foam-molded product having a stable quality and a method for producing the same, even if skin pieces having high elasticity are used for both.

In order to achieve the above object, the gist of the invention described in claim 1 is that the design surface (3a) of the tongue piece (33) protruding from the main part (31) of the two skin pieces (3) is opposed to each other. A flat tube portion (4) is formed by stitching along both side edges (33a) of the tongue pieces (33) stacked in two sheets, and the back surface (3b) including the two skin pieces (3 ) is outward. The bag-like skin (2) which is sewn into a bag shape and the design surface (3a) is turned outward by turning it over, and the flat cylindrical part (4) bent from the bottom part (231) formed by the main part (31) housed in Table-back of the bag-like epidermis (20), the snout (40) from said bag-like epidermal (20) to the foaming material (g) was injected integrally foamed molded foam and (F), In the bag-shaped skin integrated foam molded article, the two skin pieces are laminated materials in which at least one skin piece (3) includes a backing sheet member (3d) made of a foamed polyethylene sheet or a foamed polypropylene sheet. And Leaving a bottom portion area (232) of the bag-like skin of the flat tube section (4) there (2), the main portion (31) of two of said skin pieces (3), a bottom portion (23) in addition to forming to seam line (5) is sewn, site tongue of the skin piece with said backing sheet member (3d) (3) is (33) bent from said bottom portion (231) ( E), a slit (37) penetrating the backing sheet member (3d) or a concave groove (38) reaching from the back surface (3d1) of the backing sheet member (3d) to the surface (3d2). in bag-shaped integral skin foam molded article characterized by comprising provided streaking. The bag-shaped skin integrated foam molded product according to the second aspect of the present invention is the first aspect of the present invention, wherein the slit (37) or the concave groove (38) is a seam line (5) that forms the bottom surface portion (23). The tongue piece portion (33) sandwiched is provided at the base portion where the tongue piece portion (33) bends, on the line extension of the seam line (5) .
The gist of the invention described in claim 3 is that the tongue piece portion formed by overlapping the design surface (3a) of the tongue piece portion (33) projecting from the main portion (31) of the two skin pieces (3) is opposed to each other. stitched together both side edges (33a) along to form a flat tube portion (4) of (33), the back surface (3b) is sewn to the outward of the bag-like, including and two said surface skin piece (3), the table After making the bag-like skin (2) with the design surface (3a) on the outside by turning back, the flat cylindrical part (4) bent from the bottom surface part (231) formed by the main part (31) is inside the bag-like skin ( 20), set the bag-shaped skin (2) on the foaming mold (9) with the tube mouth (40) facing up, and then foam the raw material (g) from the tube mouth (40) into the bag-shaped skin (20). ) Is injected to form a foam (F) integral with the bag-like skin , and at least one skin piece (3) is foamed. Back made of polyethylene sheet or expanded polypropylene sheet A laminate comprising a sheet member (3d) Te, before or after sewing sewing the bag-like skin (2), corresponding to the site where the flat tube portion (4) is bent, the backing sheet member ( In the part (E) where the tongue piece portion (33) of the skin piece (3) having 3d) is bent, the slit (37) penetrating the backing sheet member (3d) or the backing sheet member (3d) A concave groove (38) reaching from the back surface (3d1) to the front surface (3d2) is provided in a streak shape, and then the bag-like skin (2) in an inverted state is turned over, and the flat tube portion (4) is placed in the bag. A bag-shaped skin-integrated foam-molded article characterized in that the bag-shaped skin (2) is set in a foaming mold (9) with the cylindrical mouth (40) facing up inside the shaped skin (20) . In the manufacturing method.

As in the first and third aspects of the invention, the two skin pieces are laminated materials in which at least one skin piece (3) includes a backing sheet member (3d) made of a foamed polyethylene sheet or a foamed polypropylene sheet. and the portion the skin piece having a backing sheet member (3d) tongues (3) (33) is bent from said bottom portion (231) (E), through the backing sheet member (3d) If the concave groove (38) reaching from the slit (37) or the back surface (3d1) of the backing sheet member (3d) to the front surface (3d2) is provided in a streak shape , it will spring up because it is stiff even when bent. Even the elastic member that has been elastically weakened can be smoothly set into a bag-like skin by bending the flat cylindrical portion from the bottom surface portion. Since the portion bent from the bottom portion is intensively weakened by the fragile portion of the slit (37) or the concave groove (38) , the flat tube portion is bent without the help of the external force pulled in Patent Document 2. The state of the bent corners can be autonomously held by the bag-like skin itself. When the tongue piece with the backing sheet member is bent and the flat tube is placed in the bag-like skin, the elastic restoring force is weakened by the presence of the fragile part, making it easy to bend at the bent part. In addition, since the bent corners of the bent shape are maintained, the setting of the bag-like skin to the foaming mold proceeds smoothly. Further, steps, wrinkles, and distortion do not occur in the foamed integral foam molded product such as a headrest that is foam-molded.
Further, in the laminated material including the backing sheet member (3d) made of a foamed polyethylene sheet or a foamed polypropylene sheet, the fragile portion (34) on the skin piece (3) on which the backing sheet member (3d) is present Since foamed polyethylene sheets and foamed polypropylene sheets are made of closed-cell foams and have high hardness, it is effective for the foaming material to leak out from the seam that sewn the bag-like skin during foam molding. Can be prevented. Conventionally, at the stitching part of the skin pieces, a film that wraps the seam allowance including the periphery has been attached to prevent leakage of the foaming raw material (Japanese Patent Laid-Open No. 11-225846), but such a film is not required to be attached. become. This leads to a significant cost reduction of the product. Furthermore, when a weak part such as a slit (36), a concave groove (38) is formed, the missing part is concentrated on the epidermis layer of the part (E) where the tongue part (33) is bent from the bottom part (231). This makes it possible to easily fold the skin piece at the fragile portion.
As in claim 2 , the fragile portion (34) is formed at the base portion where the tongue piece portion (33) sandwiched between the two seam lines (5) forming the bottom surface portion (23) is bent. If it is provided on the line extension of 5), the seam line and the part (E) where the flat tube part (4) bends from the bottom part (231) coincides with the line, so the circumference of the tube opening (40) is difficult to loosen. that Do not.

The bag-shaped skin-integrated foam molded product of the present invention and the manufacturing method thereof do not increase the number of parts, and do not require a special separate device, can be easily processed and formed at low cost, and the tongue piece portion can be used. even if the elastic force of two of the epidermis pieces to be formed is different, also using the skin pieces with a high resilient force in both, it can be such a number of production without any quality stable good dropping the productivity Exhibits excellent effects.

It is an expansion | deployment top view of each skin piece which concerns on a bag-shaped skin in one form of the bag-shaped skin integrated foaming molded product of the invention, and its manufacturing method. It is a back surface side perspective view of the bag-like skin formed by stitching each skin piece of FIG. FIG. 3 is an explanatory cross-sectional view in which a bag-shaped skin and stay are set in a foam mold and the mold is closed. It is explanatory sectional drawing which showed a mode that the foaming raw material was inject | poured in a bag-like skin after FIG. It is explanatory sectional drawing which showed a mode that it foam-molds after FIG. (A) is a perspective view of the headrest taken out after being removed from FIG. 5, and (B) is a view taken along the line VI-VI in (A). FIG. 7 is an alternative view of FIG. 1 to FIG. 6, (A) is an explanatory front view of the skin piece around the fragile portion, (B) is a sectional view of the main part of (A), and (C) is the skin piece of (A). FIG. 4 is an explanatory cross-sectional view in which the bag-like skin and stay formed in (1) are set and the mold is closed, and (D) is an enlarged view around the cylindrical portion of (C). FIG. 7 is another view different from FIG. 7, (A) is an explanatory front view of the skin piece around the fragile portion, (B) is a cross-sectional view of the main part of (A), and (C) is formed of the skin piece of (A). FIG. 4 is an explanatory cross-sectional view in which the bag-shaped skin and stay are set and the mold is closed, and (D) is an enlarged view around the cylindrical portion of (C). FIG. 4 is a partially enlarged view of a bag-like skin according to another embodiment, and (b) is an explanatory cross-sectional view corresponding to the enlarged view in a circle of FIG. 3 in which the bag-like skin is set in a foaming mold. (A) is explanatory sectional drawing of the bag-shaped skin of a prior art, (b) is a perspective view of the headrest using the bag-shaped skin of (b). It is explanatory sectional drawing of a prior art. It is explanatory sectional drawing of a prior art.

  Hereinafter, the bag-like skin integrated foam molded product and the manufacturing method thereof according to the present invention will be described in detail. 1 to 9 show one embodiment of a bag-like skin-integrated foam-molded product of the present invention (hereinafter also simply referred to as “skin-integrated foam-molded product”) and a manufacturing method thereof. FIG. 1 is a plan view of each skin piece, 2 is a perspective view of the back side of the bag-like skin formed by stitching the skin pieces of FIG. 1, FIG. 3 is an explanatory sectional view in which the bag-like skin is set in a foaming mold, and FIG. FIG. 5 is an explanatory cross-sectional view showing a state of foam molding after FIG. 4, FIG. 6 is a perspective view of a headrest taken out after (a) is removed, and (b) FIG. 7 to FIG. 9 are explanatory views of another embodiment and another embodiment in place of FIGS. 1 to 6. Although FIG. 1 is before sewing, it is drawn for convenience in order to make the positions of the stitch line 5 and the stitching line 6 easy to understand. In addition, hatching for displaying a cross section is omitted as appropriate.

(1) Manufacturing method of bag-shaped skin-integrated foam-molded product The manufacturing method of bag-shaped skin-integrated foam-molded product is applied to a method of manufacturing a headrest 1 having a pillow shape as shown in FIG. A bag-shaped skin 2 having two skin pieces 3 for forming a bottom surface portion 23 and a flat tube portion 4 and sewn into a bag shape, and a foaming raw material g from the tube port 40 of the flat tube portion 4 into the bag-shaped skin 20 And a foam F that is integrally foamed by injection.

  First, prior to production, a skin piece 3 and a skin piece 7 formed by flattening the bag-like skin 2 for headrest are prepared. As shown in FIGS. 1 and 6, the skin piece 3 here includes a front skin piece 3 </ b> A that forms a bottom surface portion 231 on the front side of the vehicle from the headrest front surface portion 22 where the occupant's head hits, and a vehicle rear side from the headrest rear surface portion 24 And a rear skin piece 3 </ b> B for forming a bottom surface portion 231. The skin piece 7 is prepared as a symmetrical product, and forms both side portions 25 in the headrest vehicle width direction. Tongue pieces 33 protrude from the bottom surface portion 231 formed by the respective main portions 31 on the two skin pieces 3. A certain necessary amount of seam allowances 39 and 79 are preliminarily supplemented on the periphery of the skin pieces 3 and the skin pieces 7.

  For the material of the skin piece 3 and the skin piece 7, a fabric skin or the like is used, but at least one skin piece 3 is a fabric skin 3 f for design surface formation and a foamed polyethylene sheet or foam placed on the back side. The laminated material includes a backing sheet member 3d made of a polypropylene sheet. In this embodiment, as shown in the enlarged views in the circles of FIGS. 3 and 6, a urethane slab 3e made of a thick plate of 6 mm thick urethane foam on the back surface of the design surface forming fabric skin 3f, and a film 3m is integrated and integrated. On the other hand, the rear skin piece 3B and the skin piece 7 include a design surface forming fabric skin 3f and a backing sheet member 3d made of a foamed polyethylene sheet (or a foamed polypropylene sheet) disposed on the back side. Laminated material. Specifically, the bonding urethane laminate 3c is applied to the back surface of the fabric skin 3f, and the backing member 3d, which is a foamed polyethylene resin sheet having a thickness of 2 mm, which is thinner than the urethane slab 3e, is bonded together (FIG. 3). .

  Each skin piece 3 and skin piece 7 are sewn with the back surfaces 3b and 7b facing outward, and the bag-like skin 2 is sewn (FIG. 2). The design surface 3a of the tongue piece part 33 which concerns on the two skin pieces 3 is made to oppose, and both the side edges 33a of the tongue piece part 33 which overlapped two sheets are sewn together, and the short cylindrical flat cylinder part 4 is formed. The seam line 5 forming the bottom surface portion 23 is stitched to the main portions 31 of the two skin pieces 3 while leaving the bottom surface region 232 where the flat cylindrical portion 4 is present. Further, the stitching line 6 is formed by stitching both the main portions 31 and the other skin pieces 7 to form the bag-like skin 2 as shown in FIG. Note that reference numeral 61 in FIG. 3 indicates a stitching line that forms the top portion of the headrest with the skin pieces 3A and 3B. At the same time, a streak-like fragile portion 34 that facilitates bending is provided at a portion E where the tongue piece portion 33 of at least one skin piece 3 is bent from the bottom surface portion 231 thereof. The bent portion E is a base portion of the tongue piece portion 33 or a boundary area between the tongue piece portion 33 and the main portion 31. When the bag-shaped skin 2 is set in the foaming mold 9 and the foam F is integrally formed with the bag-shaped skin 2, in FIG. 6, the bending angle that bends in a L-shaped cross section from the bottom surface portion 231 to the tongue piece portion 33. Section.

  In the present embodiment, the fragile portion 34 is provided in the rear skin piece 3B having a foamed polyethylene sheet. The fragile portion 34 is disposed at an extension of the seam line 5. Since the skin piece 3 having a foamed polyethylene sheet is used, it is effective in preventing leakage of the foaming raw material g from the perforation during foam molding. However, although the foamed polyethylene sheet is thinner than the urethane slab 3e, the foamed polyethylene sheet has a drawback that it will spring up due to its stiffness. Since the repulsive force (elastic restoring force) in the base end region of the tongue piece portion 33 formed by bending at the tip of the bottom surface portion 231 is large, the tongue piece portion P of the rear skin piece S2 does not break at the bent portion as shown in FIG. In addition, the inconvenience of falling and riding on the tongue piece P side on the front skin piece S1 side is caused. The weak part 34 eliminates this defect.

  The fragile portion 34 is a portion where the repelling force (elastic restoring force) of the skin piece 3 is weakened when the skin piece 3 is bent, and is provided on the skin piece 3 on which the backing sheet member 3d is present. . Here, a sewing machine is used, and a fragile portion 34 in the form of a dotted line as shown in FIGS. 1 and 2 is formed by a perforated (blank) perforation 35 that penetrates the skin piece 3. An empty seam perforation 35 is formed in a streak shape at a portion E where the tongue piece portion 33 on the side of the rear skin piece 3B is bent at the extension portion (extension destination) of the stitch line 5 that forms the bottom surface portion 23 by the two skin pieces 3. To form. The perforated seam 35 is provided at the base of the tongue piece 33 so as to cross the tongue piece 33 protruding from the main portion 31. A perforated perforated line 35 is continuously opened at a base portion of the tongue piece 33 close to the bottom surface 23 at a pitch of 2 mm, for example, in a dotted line shape (FIG. 1). The perforation hole 35e penetrates the portion E where the tongue piece portion 33 bends, and the repulsive force (elastic restoring force) of the skin piece 3 at that portion due to bending is weakened.

  Next, the bag-like skin 2 with the fragile portion 34 of FIG. 2 which has been provided with the fragile portion 34 and has been sewn in an inverted state is turned over so that the design surface 2a is on the outside. Further, the flat tube portion 4 is bent with respect to the bottom surface portion 231 and stored in the bag-shaped skin 20. In addition, the leg portion 81 of the stay 8 is passed through the stay hole 32 and the protruding portion is maintained, and the connecting portion 82 is accommodated in the bag-like skin 20.

Thereafter, the bag-like skin 2 with stays 8 is set on the foaming mold 9 with the bottom surface portion 23 facing upward while the molds 9a and 9b indicated by chain lines in FIG. The bag-shaped skin 2 in which the tongue piece 33 is bent in an L-shaped cross-section from the bottom surface portion 231 toward the bag-shaped skin inside 20 with the tube port 40 of the flat tube portion 4 facing upward, Set and then close the temporary mold.
A locking tool (not shown) that holds and holds the stay 8 lifts the bottom surface portion 23 of the bag-shaped skin 2 via the stay 8, and brings the bottom surface portion 23 into contact with the upper mold surface 911 of the foaming mold 9. Since the elastic restoring force at the bent corner on the tube entrance 401 side is weakened by the formation of the fragile portion 34, the tongue piece 33 is bent at the portion E where the rear skin piece 3B is bent from the bottom surface portion 231. Easy and stable.

After securing such a state, a predetermined amount of foaming raw material g (for example, liquid polyurethane foam raw material) is injected into the bag-like skin 20 through the funnel R (FIG. 4). In the figure, reference numeral 94 denotes a foaming material inlet provided in the foaming mold 9, reference numeral 90 denotes a cavity, and reference numeral 96 denotes a hinge. Thereafter, the mold is completely closed, and the foam F integrated with the bag-like skin 2 is foam-molded (FIG. 5).
The flat tube portion 4 protruding into the bag-like skin 20 is foamed by foaming, and the tube port 40 is closed by being tightened from both sides. Since the fragile portion 34 provided on the rear skin piece 3B is arranged at the bent corner portion of the bent portion E, the shape around the bent corner portion is maintained even when it is bent. The flat cylinder part 4 closes the cylinder opening 40 with foaming pressure from both sides of the flat cylinder part 4 while being vertically lowered from the bottom part 23. In this way, the tube port 40 appearing on the design surface 2a is closed beautifully to a single character, and the flat tube portion 4 is integrally fixed to the foam F. The funnel R may be removed after foam molding. Even if it is removed after foam molding, the residual pressure of the foam F disappears about the funnel tube diameter.
When foam molding is finished in this way and the mold is removed, a desired headrest 1 (bag-shaped skin integrated foam molded product) having a good appearance as shown in FIG. 6 is obtained.

FIG. 7 shows another embodiment of the weakened portion 34 in place of the weakened portion 34 of FIGS. The fragile portion 34 of FIG. 7 is formed by forming a streak-like slit 37 that facilitates bending at a portion E where the tongue piece portion 33 of the rear skin piece 3B is bent. The slit 37 is formed through the backing sheet member 3d, and an elongated linear cut is made in the firm backing sheet member 3d constituting the rear skin piece 3B. Due to the presence of the slit 37, the elastic restoring force and stiffness of the portion are weakened. When the bag-like skin 2 is set in the foaming mold 9 as shown in FIG. 3, it is the same as the fragile portion 34 formed by the perforated seam 35. The bent corner E bent from the bottom 23 to the flat tube 4 (tongue piece 33) can be stably maintained. In FIG. 7, the code | symbol 7B shows the back skin piece divided | segmented from the back skin piece 3B of FIGS.
Instead of FIG. 7, the weakened portion 34 formed by the concave groove 38 of the half slit 37 as shown in FIG. Groove 38 extending from the back surface 3d ₁ of backing sheet member 3d to its surface 3d ₂ closer is formed. The concave groove 38 is manufactured using a hot press, specifically, a Thomson type with a stroke adjusted. The groove width of the concave groove 38 is made larger than that of the slit 37, and the bent corner portion E formed at the base of the tongue piece portion 33 constituting the flat cylindrical portion 4 is the same as in the case of the slit 37 and the empty stitch perforation. The shape can be maintained.

1 to 6, the perforation 35 is formed by blank stitching. However, as shown in FIG. 9, the fragile portion 34 may be formed by the stitch 36 formed by passing the skin piece 3 and using the sewing thread 36 a. it can. By forming the stitches 36 with the sewing thread 36a, as shown in the enlarged view of FIG. 9 (b) in which the bag-like skin 2 is set on the foaming mold 9, the rear skin piece 3B is bent at the portion E where the stitch 36 is located. As a result, the elasticity and stiffness of the backing sheet member 3d are weakened. Reference numeral 36 j indicates a recess narrowed by the stitch 36. The bent corner portion E having an L-shaped cross section formed by bending the tongue piece portion 33 of the flat tube portion 4 with respect to the bottom surface portion 23 can be maintained by the presence of the stitch 36.
In addition, about the manufacturing method of the headrest (bag-shaped skin integral foam molding product) using the weak part 34 shown in the same figure in FIGS. 7-9, the other structure is the same as description of FIGS. The explanation is omitted. 1 to 6 indicate the same or corresponding parts.

(2) Bag-shaped skin-integrated foam-molded product The bag-shaped skin-integrated foam-molded product 1 includes the bag-shaped skin 2, the fragile portion 34, and the foam F. Can be built with. This embodiment is applied to a headrest as shown in FIGS.

The headrest 1 obtained by the headrest manufacturing method includes the bag-shaped skin 2, the foam F, and the fragile portion 34 as described above.
The bag-like skin 2 is a sewing skin that is formed into a bag shape including two skin pieces 3. The bag-shaped skin 2 of FIGS. 1 and 2 is formed by two skin pieces 3 and two skin pieces 7. Of course, the bag-like skin 2 can be formed by only two skin pieces 3. The bag-like skin 2 can also be formed by two skin pieces 3 and one or more skin pieces 7. Tongue pieces 33 projecting from the main part 31 extend to the two skin pieces 3. A flat cylindrical portion is formed by sewing the tongue pieces 33 extending from the bottom surface portion 231 formed by the respective main portions 31 so that the design surface 3a faces each other along the side edges 33a of the tongue piece portions 33 formed as two overlapping portions. 4 is formed.

  And as for the said skin piece 3, at least one said skin piece 3 is the backing sheet | seat member 3d which consists of the fabric skin 3f for design surface formation, and the sheet | seat made from a foaming polyethylene sheet or a foaming polypropylene sheet distribute | arranged to this back side. It is set as the laminated material containing (FIG. 3). Although it can also be set as the laminated material which contains the backing sheet member 3d with respect to all the skin piece 3 and the skin piece 7, it is limited to the back skin piece 3B and the two skin pieces 7 here. Since the front skin piece 3A hits the occupant's head, the front skin piece 3A pursues comfort. As described above, the foam of the urethane slab 3e that is soft and thick is lined on the fabric skin 3f.

  The fragile portion 34 is a streak line provided for facilitating folding at a portion E where the tongue piece portion 33 of at least one of the skin pieces 3 is bent (FIGS. 1 to 3). When sewing the bag-shaped skin 2, the stitch line 5 that forms the bottom surface portion 23 on the main portions 31 of the two skin pieces 3, leaving the bottom surface area 232 of the bag-shaped skin 2 where the flat tube portion 4 exists. The fragile portion 34 is formed at a portion E where the tongue piece portion 33 is bent from the bottom surface region 232. A streak-like fragile portion 34 that facilitates bending is provided at a portion E where the tongue piece portion 33 of at least one of the skin pieces 3 is bent. Of course, the fragile portions 34 may be provided on both skin pieces 3.

  In the present embodiment, a fragile portion 34 having a streak shape formed by a perforated seam 35 that penetrates the skin piece 3 is formed. And the weak part 34 is provided in the outer skin piece 3 in which the backing sheet member 3d of a polyethylene foam sheet exists, that is, the rear skin piece 3B. The fragile portion 34 is provided at an extension of the seam line 5, specifically, at the base portion where the tongue piece portion 33 sandwiched between the two seam lines 5 and 5 forming the bottom surface portion 23 is bent.

The fragile portion 34 can be formed with the stitches 36 formed by stitching through the one skin piece 3 by using the sewing thread 36a in addition to the perforated perforated line 35 (FIG. 9). . Here, it is more preferable that a fragile portion 34 including the perforation 35 and the stitch 36 is provided on the line extension of the seam line 5. When the fragile portion 34 is provided in the extension portion of the stitch line 5, the stitch line 5 and the portion E where the flat tube portion 4 is bent from the bottom surface portion 231 coincide with each other on the line, so that the periphery of the tube opening 40 becomes difficult to loosen. It is. Regarding the stitch 36, when the color of the fabric skin 3f is, for example, brown and it is difficult to match the color with the stitching thread 36a, the position of FIG. The proximal end portion of the tongue piece portion 33 that is recessed slightly downward is more preferable. This is because the stitching thread 36a is hidden and the quality can be kept good.
Further, the fragile portion 34 may be a streak line formed by a slit 37 penetrating the backing sheet member 3d (FIG. 7). May be a streaky weakened portion 34 from the back surface 3d ₁ formed by the groove 38 reaching its surface 3d ₂ side of the backing sheet member 3d (FIG. 8).
Any weak part 34 functions as a weak part 34 that facilitates bending at a part E where the tongue 33 is bent from the bottom part 231. As a result, it is easy to set the bag-shaped skin 2 on the foaming mold 9, and a product with good quality that does not cause defects such as the step D can be obtained. When the bag-shaped skin 2 is set upside down on the foaming mold 9, the outer surface of the bag-shaped skin 2 comes into contact with the mold surface 91 as shown in FIG. At this time, maintaining the shape of the bent portion bent from the bottom surface portion 231 so that the tongue piece portion 33 hangs down is achieved by providing the fragile portion 34. Such a state is maintained, and the foam F is integrally foamed with the bag-shaped skin 2.

The foam F is a lump of plastic foam that is integrally foam-molded with the bag-shaped skin 2 by injecting the foaming raw material g into the bag-shaped skin 20 from the tube opening 40 of the flat cylindrical portion 4 formed by the tongue piece 33. (Figure 5). As described above, the rear skin piece 3B of the flat cylindrical portion 4 employs a laminated material including a backing sheet member 3d that is stiff and springs up even when bent, but the portion E bent from the bottom surface portion 231 is A fragile portion 34 is formed. When the bag-like skin 2 in which the stay 8 is inserted and set is turned upside down and set in the foaming mold 9 (FIG. 3), a bent corner E is formed and maintained from the bottom surface portion 23 by the fragile portion 34, and the inside of the bag-like skin 20, the flat cylindrical portion 4 hangs down substantially vertically. The flat cylindrical portion 4 does not have the distorted shape in which the step portion D in FIG. 10 exists, but hangs vertically from the bottom surface portion 23.
When the foaming raw material g is injected into the bag-shaped skin 20 from the tube port 40 while maintaining such a state (FIG. 4), the foaming raw material g rises in the foam molding process, and both sides of the flat cylindrical portion 4 are disposed. The foam F in which the tube port 40 is closed to a single character by the foaming pressure is foam-molded. By the foam F, the tube port 40 is self-sealed in a straight shape as shown in FIG. 6 (a).

Thus, a foam F in which the connecting portion 82 of the stay 8 is embedded in the bag-shaped skin 20 is formed, and the foam F is formed on the inner surface of the bag-shaped skin 2 and the outer surface of the flat cylindrical portion 4 shown in FIG. To the back surface 3b). Other configurations are the same as (1) the description of the method for producing the bag-like skin integrated foam molded product, and the description thereof is omitted.
The headrest (foam F integrated with the bag-shaped skin) includes the bag-shaped skin 2, the fragile portion 34, and the foam F, and the tongue piece portion 33 of the bag-shaped skin 2 with the flat cylindrical portion 4 is bent from the bottom surface portion 231. By providing the fragile portion 34 at the corner E, the tube opening 40, specifically, the tube entrance 401 is closed cleanly, and a desired product without a step D is finished.

(3) Effect The bag-shaped skin-integrated foam-molded product configured as described above and the manufacturing method thereof have a streak shape that facilitates bending at a portion E where the tongue piece portion 33 of at least one skin piece 3 is bent from the bottom surface portion 231. Since the fragile portion 34 is provided, the flat cylindrical portion 4 can be smoothly directed from the bottom surface portion 231 to the bag-shaped epidermis 20. As shown in FIG. 3, since the flat cylindrical portion 4 hangs down with the bottom surface portion 231 facing upward, the step D cannot be formed around the cylindrical entrance 401 of the bag-shaped skin 2 and can be stored in a beautiful shape. The bag-shaped skin 2 is turned upside down and set in the foaming mold 9, and the foam raw material g is injected into the bag-shaped skin 20 from the tube port 40 and foam-molded, and the bag-shaped skin integrated foam molded product 1 (headrest) is the tube port 40. Is closed to a single character, resulting in a product of good quality that does not generate the step D, wrinkles W, and warp Y described in the prior art (FIG. 6). A high-quality bag-shaped skin-integrated foam-molded product 1 can be stably produced.
In addition, it is only necessary to provide the fragile portion 34, and no separate member as in Patent Document 1 is required, and there is no cost increase due to an increase in parts and no burden of inventory management. Further, the tensioning device of Patent Document 2 is not required, the cost of the device is not required, and it is not necessary to add a pulling process, leading to an improvement in productivity.

  Even if a laminated material provided with a backing sheet member 3d made of a foamed polyethylene sheet or a foamed polypropylene sheet is used as the skin piece 3, a streaky fragile portion 34 is formed at a portion E where the tongue piece portion 33 is bent from the bottom surface portion 231. By providing, the bag-shaped skin-integrated foam-molded article 1 with good quality can be obtained. When the tongue portion 33 where the backing sheet member 3d is present is bent and the flat tube portion 4 is disposed in the bag-like skin 20, the elastic restoring force is weakened due to the presence of the fragile portion 34, and the portion E is bent. In addition to facilitating bending, the bent corners of the bent shape are maintained, so that the setting of the bag-shaped skin 2 to the foaming mold 9 proceeds smoothly. In addition, the step D, the wrinkle W, and the warp Y are not generated in the bag-shaped skin integral foam molded product such as the headrest 1 that is foam-molded.

Also, it weakened portions 34 are formed in groove 38 to reach either formed by a slit 37 which is passed through the backing sheet member 3d, or from the back surface 3d ₁ of backing sheet member 3d to its surface 3d ₂ closer The fragile portion 34 can be easily formed. Since the fragile portions 34 such as the perforated perforations 35, the slits 36, and the concave grooves 38 are formed in the skin layer of the bent corner portion E of the skin piece 3, the resilience residual of the skin piece 3 accompanying the bending Stress can be easily removed.
Even if the fragile portion 34 is formed by an empty stitch perforation 35 that penetrates the skin piece 3 or is formed by a stitch 36 that penetrates the skin piece 3 and uses a sewing thread 36a, it is easily fragile. Portions 34 can be formed. In the case where the fragile portion 34 is formed by the empty stitches 35 and the stitches 36, the same sewing machine as that for stitching the stitch line 5 can be used for processing, so that it is not necessary to introduce new work equipment.

  Note that the perforated perforation 35 and the slit 37 are provided with a perforation hole 35e and a slit 37 penetrating the skin piece 3, and there is a concern that the foaming raw material g leaks out of the bag-like skin 2. In the present invention, leakage is suppressed by the position of the fragile portion 34. Since the fragile portion 34 is disposed at the bent portion E, the inner surface side of the skin piece 3 of the bent portion E is compressed and the perforation 35 and the slit 37 are in the closing direction. The enlarged view in the circle of FIG. 3 shows the perforation 35 in an easy-to-understand manner. Actually, it becomes like the enlarged view of the circle in FIG. 6, and the inner surface side perforation 35 of the rear skin piece 3B is closed. Leakage of the foaming raw material g to the outside of the bag-shaped skin 2 during foam molding is suppressed. By providing the fragile portion 34 at the bent corner E, the shape retention of the bent corner obtained by bending the tongue piece 33 is maintained while suppressing leakage of the foaming raw material g.

In addition, if the fragile portion 34 is provided on the outer skin piece 3 on which the backing sheet member 3d made of a foamed polyethylene sheet or a foamed polypropylene sheet is present, the bag-like skin is formed from the perforation 35, the stitch 36, etc. during foam molding. 2 has an effect of preventing the foaming raw material g from leaking out. For example, the foamed polyethylene sheet is a closed-cell type foam, and is harder than the urethane slab 3e, so that the perforated perforation 35 and the perforations formed by the stitches 36 at the time of foam molding are removed from the bag-like skin 2. The leakage of foaming material can be completely prevented. Conventionally, a film that wraps the seam allowance including its periphery has been attached at the stitched portion between the skin pieces to prevent leakage of the foaming raw material g (Japanese Patent Laid-Open No. 11-225846). It becomes unnecessary. The dough stopper piece (Japanese Patent Laid-Open No. 8-66572) for preventing leakage of the foaming raw material g adhered around the stay hole 32 in FIG. This leads to a significant cost reduction of the product. Furthermore, since the foamed polyethylene sheet is a closed-cell type, there is no need to attach the film 3m to the back surface side of the skin piece 3 in contact with the foam F like the urethane slab 3e.
Furthermore, when viewed from the quality aspect, the skin piece 3 using a foamed polyethylene sheet is hard, and thus has the merit that wrinkles are less likely to occur than when the urethane slab 3e is used.
As described above, the present bag-like skin-integrated foam-molded product and the method for producing the same exhibit the numerous excellent effects described above and are extremely useful.

  The present invention is not limited to those shown in the above-described embodiment, and various modifications can be made within the scope of the present invention depending on the purpose and application. The shape, size, number, material, etc. of the bag-like skin 2, skin piece 3, main part 31, tongue piece part 33, fragile part 34, flat tube part 4, stitch line 5, foam F, etc. are adapted to the application. Can be selected as appropriate. Although the embodiment is applied to a headrest, the embodiment can also be applied to a bag-shaped skin-integrated foamed molded article 1 such as an armrest.

1 Bag-shaped skin integrated foam-molded product (headrest)
2 Bag-shaped skin 23 Bottom part 231 Bottom part 3 Skin piece 31 Main part 34 Fragile part 35 Perforation 36 Stitch 37 Slit 38 Groove 4 Flat tube part 5 Seam line E Bent part (bent corner)
F Foam g Raw material for foaming

Claims (3)

The design surface (3a) of the tongue piece (33) that protrudes from the main part (31) of the two skin pieces (3) is opposed to each other, along the side edges (33a) of the tongue piece (33) that are overlapped. The flat cylindrical part (4) is formed by stitching, and the back surface (3b) including the two skin pieces (3) is sewn in a bag shape facing outward, and the design surface (3a) is turned outward by turning it over. a bag-like skin (2), matches the flat tubular portion which is bent from the bottom portion (231) of said main portion (31) is made (4) in Table-back of the bag-like epidermis (20), the snout (40 ) is integrally foam molded by injecting the foaming material (g) said bag-like in the epidermis to (20) from the foam and (F), in the bag-like integral skin foam molded article comprising,
The two skin pieces are laminated materials including at least one skin piece (3) including a backing sheet member (3d) made of a foamed polyethylene sheet or a foamed polypropylene sheet,
And the bottom part (23) is left on the main part (31) of the two skin pieces (3), leaving the bottom part area (232) of the bag-like skin (2) where the flat tube part (4) is present. In addition to the stitch line (5) forming the stitching,
Slit penetrating in the region (E) bent from the tongue portion (33) of said bottom portion (231) of said backing sheet member the skin piece having a (3d) (3), said backing sheet member (3d) (37) or bag-like integral skin back surface grooves extending from (3d1) to its surface (3d2) closer (38), characterized in that the thus provided for the streaks of the backing sheet member (3d) Foam molded product. The slit (37) or the recessed groove (38) is the seam at the base portion where the tongue piece portion (33) is bent between both seam lines (5) forming the bottom surface portion (23). The bag-shaped skin-integrated foam-molded product according to claim 1 or 2, provided on a line extension of the line (5) . The design surface (3a) of the tongue piece (33) that protrudes from the main part (31) of the two skin pieces (3) is opposed to each other, along the side edges (33a) of the tongue piece (33) that are overlapped. stitching to form a flat tube portion (4), the back surface (3b) is sewn to the outward of the bag-like, including and two said surface skin piece (3), the design surface (3a) is outside the table barbs after a bag-like skin (2), wherein the flat tubular portion which is bent from the bottom portion (231) of said main portion (31) make (4) accommodated in the bag-like skin (20), the snout (40) Set the bag-shaped skin (2) in the foamed mold (9) with the top facing up, and then inject the foaming raw material (g) from the tube port (40) into the bag-shaped skin (20) to integrate with the bag-shaped skin. In the method for producing a bag-like skin integrated foam molded product for foam molding of the foam (F),
The two skin pieces are laminated materials including at least one skin piece (3) including a backing sheet member (3d) made of a foamed polyethylene sheet or a foamed polypropylene sheet,
Before or after sewing sewing the bag-like skin (2), wherein the flat tube portion (4) in correspondence with the portion where the bent tongue of the skin piece with said backing sheet member (3d) (3) From the rear surface (3d1) of the slit (37) penetrating the backing sheet member (3d) or from the back surface (3d1) of the backing sheet member (3d) to the portion (E) where the part (33) is bent Recessed groove (38) is provided in a streak shape, and then the bag-shaped epidermis (2) is turned upside down, and the flat cylindrical portion (4) is stored in the bag-shaped epidermis (20), 40. A method for producing a bag-like skin-integrated foam-molded product, wherein the bag-like skin (2) is set in the foaming mold (9) with the top facing 40).

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