JP6532756B2 - Apparatus for producing foam molded article, method for producing foam molded article - Google Patents

Description

  The present invention relates to a device for producing a foam, a method for producing a foam and a foam.

  DESCRIPTION OF RELATED ART Conventionally, the manufacturing apparatus of the foam-molded body described, for example in following patent document 1 is known. The manufacturing apparatus includes a cavity between a plurality of molds, the cavity being defined by the cavity surface of each of the plurality of molds, and a protrusion is formed on the cavity surface.

JP 2003-94452 A

  However, in the above-described conventional apparatus for producing a foam molded article, when the foam molded article is formed in the cavity, the plurality of molds are opened, and the foam molded article is removed when the foam molded article is removed from the cavity surface. There is room for improvement in making it easy to mold.

  The present invention has been made in view of the above-described circumstances, and it is an object of the present invention to make it easy to release a foam molded article.

In order to solve the above-mentioned subject, the present invention proposes the following means.
The apparatus for manufacturing a foam molded article according to the present invention comprises a plurality of molds provided with a cavity defined by a cavity surface of each of the plurality of molds, wherein a protrusion is formed on the cavity surface. It is a manufacturing apparatus of a body, The groove formation part which protrudes from the said cavity surface is formed in the said cavity surface, While the said protrusion part is formed in the said groove formation part by an elastic body, Among the said protrusion parts It is characterized in that a thin portion thinner than the other portion of the protrusion is formed in a part or a plurality of parts of.

In this case, since the projecting portion is formed of an elastic body, when the plurality of molds are opened after molding the foamed molded body in the cavity, the foamed molded body is elastically deformed from the cavity surface and the projecting portion is elastically deformed. It can be made to die off while Moreover, since the thin-walled portion is formed on a part or a plurality of portions of the projecting portions, the thin-walled portion of the projecting portions can be positively elastically deformed, and the projecting portions can be easily elastically deformed. Therefore, when the foam molded body is removed from the cavity surface, for example, it becomes possible to suppress the sticking of the protrusion to the foam molded body, etc., while suppressing damage to the foam molded body. It can be made easy to be removed from the cavity surface.
Further, as described above, since the foam molded body can be released from the cavity surface while elastically deforming the projecting portion, it is possible to suppress an excessive load from being applied to the projecting portion at the time of demolding of the foam molded body. As a result, the entire protrusion can be formed thin. Thereby, for example, when forming a slit part in a foaming molding by a projection part, thinness of a slit part can be set up freely freely.

  The thin portion may be disposed at a proximal end of the protrusion.

  In this case, since the thin-walled portion is disposed at the base end portion of the projecting portion, when the molded foam is removed from the cavity surface, the entire projecting portion can be thinned by elastically deforming the thin-walled portion. It can be elastically deformed greatly from the point of origin. This makes it possible, for example, to further prevent the protrusion from being caught by the foam molded body when the foam molded body is demolded from the cavity face, and makes the foam molded body easier to be demolded from the cavity surface. Can.

An upper mold and a lower mold are provided as the plurality of molds, and the groove forming portion and the projection are formed on the cavity surface of the lower mold and project from the lower mold toward the upper mold It is also good.

  In this case, the protrusion is formed on the cavity surface of the lower mold and protrudes from the lower mold toward the upper mold. Therefore, when the foam molded body is removed from the cavity surface, the foam molded body is removed from the cavity face by pulling up the foam molded body disposed on the cavity face of the lower mold toward the vertical upper side. As a result, the foam molded body can be more easily removed from the cavity surface.

The foam molded body includes a first foam and a second foam integrally molded, and the groove forming portion and the protrusion form the cavity as a first cavity for molding the first foam; A second cavity for forming the second foam may be partitioned, and the protrusion may gradually extend toward the first cavity side as it goes to the upper mold side.

  In this case, the protrusion gradually extends toward the first cavity as it goes to the upper mold side. Therefore, when the foam molded body disposed on the cavity surface of the lower mold is pulled upward toward the vertical upper side, the first foam of the foam molded body is made to overlie the protruding portion in the vertical direction, thereby forming the foam. The molded body can be removed from the cavity surface. Here, when the first foam has a hardness lower than that of the second foam, for example, the first foam is flexibly deformed to cause the first foam to vertically ride over the protrusion. (1) Damage to the foam can be suppressed. Thereby, the foam molded body can be formed with high accuracy.

  The protrusion may be gradually thinner or thicker toward the tip of the protrusion, and the protrusion may be curved.

In these cases, since the protrusions are formed in various shapes, when the slits are formed in the foam molded article by the protrusions, the shape of the slit can be selected from various shapes.
In addition, when the protrusion is gradually thinned toward the tip of the protrusion, it becomes possible to elastically deform the tip of the protrusion positively, and the molded foam is removed from the cavity surface It can be made easy.
In addition, when the protrusion is gradually thickened toward the distal end of the protrusion, the base end of the protrusion can be positively elastically deformed so that the entire protrusion can be significantly elastically deformed. Thus, the foam can be more easily removed from the cavity surface.
Furthermore, when the protrusion is curved, the protrusion can be elastically deformed so as to change the curvature of the protrusion, and the foam can be more easily removed from the cavity surface.

  The method for producing a foam molded article according to the present invention is a method for producing a foam molded article, wherein the foam molded article is formed using the apparatus for producing a foam molded article, and the foam molded article is molded in the cavity. The plurality of molds may be opened, and the foam molded body may be released from the cavity surface while elastically deforming the protrusion.

  In this case, after the foam molded body is formed in the cavity, the plurality of molds are opened, and the foam molded body is removed from the cavity surface while elastically deforming the protrusion. It can be made easy to mold.

  The method for producing a foam molded article according to the present invention is characterized by being formed by the method for producing the foam molded article.

  According to the present invention, the foam molded article can be easily removed from the mold.

It is sectional drawing of the pad for sheets which concerns on one Embodiment of this invention. It is sectional drawing of the metal mold | die which forms the pad for sheets shown in FIG. It is an enlarged view of the protrusion part which comprises the metal mold | die shown in FIG. It is sectional drawing of the metal mold | die which forms the pad for sheets shown in FIG. 1, Comprising: It is a figure which shows the state which shape | molded the pad for sheets in the cavity. It is an enlarged view which shows the 1st example of the attachment structure of the protrusion part shown in FIG. It is an enlarged view which shows the 2nd example of the attachment structure of the protrusion part shown in FIG. It is an enlarged view which shows the 3rd example of the attachment structure of the protrusion part shown in FIG. It is an enlarged view which shows the 4th example of the attachment structure of the protrusion part shown in FIG. It is sectional drawing of the metal mold | die which concerns on the 1st modification of this invention, Comprising: It is an enlarged view of a protrusion part. It is sectional drawing of the pad for sheets formed of the metal mold | die shown in FIG. 9, Comprising: It is an enlarged view of a slit part. It is sectional drawing of the metal mold | die which concerns on the 2nd modification of this invention, Comprising: It is an enlarged view of a protrusion part. It is sectional drawing of the pad for sheets formed of the metal mold | die shown in FIG. 11, Comprising: It is an enlarged view of a slit part. It is sectional drawing of the metal mold | die which concerns on the 3rd modification of this invention, Comprising: It is an enlarged view of a protrusion part. It is sectional drawing of the pad for sheets formed of the metal mold | die shown in FIG. 13, Comprising: It is an enlarged view of a slit part.

Hereinafter, a seat pad 10 according to an embodiment of the present invention will be described with reference to FIGS. 1 to 4.
As shown in FIG. 1, the sheet pad 10 is formed of a foam molding. Examples of the foam-molded body include soft resin foam-molded bodies obtained by foaming and molding resin materials, such as flexible polyurethane foam (soft resin).

  The seat pad 10 is employed, for example, as a seat attached to a car (vehicle). The seat pad 10 is provided with a seating surface 11 (loading surface) with which an occupant seated on the seat abuts. In the present embodiment, a cushion pad is adopted as the seat pad 10, and the seating surface 11 faces the upper side in the vertical direction with the seat pad 10 attached to the vehicle, and the longitudinal direction and the left and right direction of the vehicle In the direction, the load of the occupant acts on the seat pad 10 from the upper side.

The seat pad 10 is formed in a flat rectangular parallelepiped shape, and the direction orthogonal to the seating surface 11 in the seat pad 10 is the thickness direction H of the seat pad 10.
The seat pad 10 includes a body 12 (first foam) and a side 13 (second foam) integrally formed of different materials. The body portion 12 has a hardness lower than that of the side portion 13. The side portion 13 is formed along the outer peripheral edge of the main body portion 12 and sandwiches the main body portion 12 from both sides in the seat width direction B (first lateral direction) along the seating surface 11.

The main body portion 12 and the side portion 13 are partitioned by the hanging groove 14 and the slit portion 15. The hanging groove 14 extends in the orthogonal direction (one direction) orthogonal to the seat width direction B along the seating surface 11 and is open in the seating surface 11 and is opposite to the mounting surface side along the thickness direction H from the seating surface 11 It is depressed toward the
The slit portion 15 is opened at the bottom surface of the hanging groove 14 and is recessed from the bottom surface toward the anti-loading surface side along the thickness direction H. The slit portion 15 extends inward from the outer side of the sheet pad 10 along the sheet width direction B, and gradually extends in the thickness direction H toward the inner side in the sheet width direction B. It extends towards the

  The outer end of the slit portion 15 in the sheet width direction B is open to the surface of the sheet pad 10, and the inner end of the slit portion 15 in the sheet width direction B is not on the surface of the sheet pad 10. It is an opening. The outer end of the slit portion 15 in the sheet width direction B is thinner than the other portions of the slit portion 15.

  The main body portion 12 and the side portion 13 are partitioned along the hanging groove 14 and the slit portion 15 and an imaginary line extending along the slit portion 15 from the inner end in the sheet width direction B in the slit portion 15 There is. The side portion 13 is embedded in the opposite side of the main body portion 12 along the thickness direction H at both end portions in the sheet width direction B of the main body portion 12.

  According to such a seat pad 10, the seat pad 10 is deformed by deforming the seat pad 10 so as to narrow the slit portion 15 in the thickness direction H when the occupant is seated on the seating surface 11. Thus, it is possible to appropriately bend the seat pad 10 while suppressing the hardness felt from the above, and for example, it is possible to improve the sitting comfort at the time of sitting or cornering.

  Next, a mold 20 (a device for producing a foam molded article) for forming the sheet pad 10 will be described with reference to FIGS. 2 to 4.

  As shown in FIGS. 2 to 4, the mold 20 includes a cavity 23 defined by a cavity surface 22 of each of the plurality of molds 21 between the plurality of molds 21. The cavity 23 is formed in the same shape and the same size as the seat pad 10. In the present embodiment, an upper mold 24 and a lower mold 25 are provided as the plurality of molds 21. A seating surface forming portion 26 (loading surface forming portion) which forms the seating surface 11 of the seat pad 10 is provided on the cavity surface 22 of the lower mold 25. The plurality of molding dies 21 open and close in a thickness direction H (opening and closing direction of the plurality of molding dies) orthogonal to the seating surface forming portion 26 and along the vertical direction.

The seating surface forming portion 26 is formed with a groove forming portion 27 and a projecting portion 28 (slit forming portion).
The groove forming portion 27 forms the hanging groove 14. The groove forming portion 27 protrudes from the seating surface forming portion 26 toward the upper mold 24 side. The groove forming portions 27 are arranged in a pair at intervals in the seat width direction B along the seating surface forming portion 26. The pair of groove forming portions 27 have the same shape and the same size.

  The projecting portion 28 is formed of an elastic body, and forms the slit portion 15 and forms an interface between the main body portion 12 and the side portion 13. In the present embodiment, the projecting portion 28 is formed of, for example, PP (polypropylene), PET (polyethylene terephthalate), or the like, and is formed so as to be easily detached from the sheet pad 10 molded in the cavity 23.

The protrusion 28 protrudes from the cavity surface 22 into the cavity 23. The protrusion 28 is formed on the cavity surface 22 of the lower mold 25 and protrudes from the lower mold 25 toward the upper mold 24. The projecting portion 28 projects from the seating surface forming portion 26 of the cavity surface 22 of the lower mold 25 and extends inward from the outside of the cavity 23 along the seat width direction B. The protrusion 28 extends obliquely with respect to the thickness direction H, and gradually extends inward in the sheet width direction B as it goes from the lower die 25 to the upper die 24.
The projecting portion 28 is formed in a plate shape whose front and back surfaces face in the thickness direction H. The protrusion 28 extends straight along the seating surface forming portion 26 and in a direction (one direction) perpendicular to the sheet width direction B in a plan view of the cavity surface 22 in which the protrusion 28 is formed.

  The groove forming portion 27 and the projecting portion 28 divide the cavity 23 into a first cavity 23 a for forming the main body portion 12 and a second cavity 23 b for forming the side portion 13. The first cavity 23 a is partitioned in the central portion in the sheet width direction B of the cavity 23, and the second cavity 23 b is partitioned in both sides in the sheet width direction B of the cavity 23. The protrusion 28 gradually extends toward the first cavity 23 a as it goes to the upper die 24 side.

  A thin portion 29 which is thinner than other portions of the protrusion 28 is formed on a part or a plurality of parts of the protrusion 28. In the illustrated example, the protruding portion 28 has the same thickness of the portion excluding the thin portion 29, and a portion of the protruding portion 28 is a limited thin portion 29. The thin portion 29 is disposed at the proximal end of the protrusion 28. The thin portion 29 is formed by thinning the projecting portion 28 from both sides in the thickness direction (thickness direction H) of the projecting portion 28. The step part which connects the thin part 29 and other parts among the protrusion parts 28 is formed in curved surface shape.

  In the method of manufacturing a sheet pad (the method of manufacturing a foam molded article) of forming the sheet pad 10 using the mold 20, as shown in FIG. 4, after forming the sheet pad 10 in the cavity 23, The plurality of molds 21 are opened, and the sheet pad 10 is released from the cavity surface 22 while elastically deforming the protrusion 28.

As described above, according to the mold 20 according to the present embodiment, since the projecting portion 28 is formed of an elastic body, after the sheet pad 10 is formed in the cavity 23, the plurality of molds 21 are formed. When the mold is opened, the sheet pad 10 can be released from the cavity surface 22 while elastically deforming the protrusion 28. Moreover, since the thin-walled portion 29 is formed on a part or a plurality of portions of the projecting portion 28, the thin-walled portion 29 of the projecting portion 28 is positively elastically deformed and the projecting portion 28 is easily elastically deformed. be able to.
Therefore, when the sheet pad 10 is removed from the cavity surface 22, for example, it is possible to suppress the protrusion 28 from being caught on the sheet pad 10, and the like, while suppressing damage to the sheet pad 10. The seat pad 10 can be easily removed from the cavity surface 22. In the present embodiment, by forming the stepped portion of the projecting portion 28 in a curved surface shape, it is possible to effectively suppress the hooking on the projecting portion 28 when the sheet pad 10 is released from the mold.

  Further, as described above, since the sheet pad 10 can be released from the cavity surface 22 while elastically deforming the projecting portion 28, an excessive load is applied to the projecting portion 28 when the sheet pad 10 is removed. Can be suppressed, and the entire protrusion 28 can be formed thin. Therefore, as in the present embodiment, for example, when the slit portion 15 is formed in the sheet pad 10 by the projecting portion 28, the thinness of the slit portion 15 can be set with a high degree of freedom. As a result, for example, by forming the slit portion 15 thin, it is possible to suppress a sense of incongruity which the occupant has when sitting, by the slit portion 15 being formed.

  Further, since the thin-walled portion 29 is disposed at the base end of the projecting portion 28, when the sheet pad 10 is released from the cavity surface 22, the entire projecting portion 28 can be formed by elastically deforming the thin-walled portion 29. Can be largely elastically deformed starting from the thin portion 29. As a result, when the sheet pad 10 is removed from the cavity surface 22, for example, it is possible to further suppress the protrusion 28 from being caught by the sheet pad 10, and the sheet pad 10 can be made closer to the cavity surface 22. It can be made easy to demold.

  Further, a projection 28 is formed on the cavity surface 22 of the lower mold 25 and protrudes from the lower mold 25 toward the upper mold 24. Therefore, when the sheet pad 10 is removed from the cavity surface 22, the sheet pad 10 disposed on the cavity surface 22 of the lower mold 25 is pulled upward toward the vertical upper side to form the cavity for the sheet pad 10. It is possible to release the mold from the surface 22, and the sheet pad 10 can be more easily released from the cavity surface 22.

  Further, the protrusion 28 gradually extends toward the first cavity 23 a as it goes to the upper die 24 side. Therefore, when pulling up the seat pad 10 disposed on the cavity surface 22 of the lower die 25 upward in the vertical direction, the main body 12 of the seat pad 10 is caused to ride the projection 28 in the vertical direction. Thus, the seat pad 10 can be released from the cavity surface 22. Here, since the hardness of the main body portion 12 is lower than that of the side portions 13, when the main body portion 12 vertically climbs the projecting portion 28, for example, the main body portion 12 is flexibly deformed and the main body portion 12 is damaged. It can be suppressed to occur. Thus, the seat pad 10 can be formed with high accuracy.

  The technical scope of the present invention is not limited to the above embodiment, and various modifications can be made without departing from the scope of the present invention.

For example, mounting structures 100, 110, 120, and 130 as shown in FIGS. 5 to 8 can be adopted as the mounting structure of the protrusion 28 to the cavity surface 22.
In the first example of the mounting structure 100 shown in FIG. 5, the mounting body 101 is extended from the proximal end of the projecting portion 28, and the mounting body 101 is fitted in the mounting hole 102 formed in the groove forming portion 27. It is done.
In the second example of the mounting structure 110 shown in FIG. 6, in addition to the mounting structure of the first example, the mounting body 101 is fixed to the groove forming portion 27 via the bolt 103. The bolt 103 is inserted into the groove forming portion 27 in the sheet width direction B and screwed.
In the third example of the mounting structure 120 shown in FIG. 7, the mounting body 101 is extended from the base end of the projecting portion 28, and the magnets 104 magnetically attached to both the mounting body 101 and the groove forming portion 27. It is arranged.
In the fourth example of the mounting structure 130 shown in FIG. 8, the projecting portion 28 and the groove forming portion 27 are integrally formed, and the magnets 104 mutually magnetically attached to both the groove forming portion 27 and the lower mold 25 are arranged. It is done.
The projecting portion 28 can be detachably attached to the cavity surface 22.

Moreover, as a modification of the pad 10 for sheets formed of the metal mold | die 20 and the metal mold | die 20, the structure shown to FIGS. 9-14 can be employ | adopted.
In the mold 30 according to the first modification shown in FIG. 9, the protrusion 28 is gradually thinned toward the tip of the protrusion 28, and the thin portion 29 is provided at the tip of the protrusion 28. It is done. As a result, as shown in FIG. 10, it is possible to form the sheet pad 31 in which the slit portion 15 gradually becomes smaller in the thickness direction H as it goes from the outer side to the inner side in the sheet width direction B.
In the mold 40 according to the second modification shown in FIG. 11, the projecting portion 28 is gradually thickened toward the distal end of the projecting portion 28, and the thin portion 29 is the proximal end of the projecting portion 28. Provided in As a result, as shown in FIG. 12, it is possible to form the sheet pad 41 in which the slit portion 15 gradually increases in the thickness direction H as it goes from the outer side to the inner side in the sheet width direction B.
In the mold 50 according to the third modification shown in FIG. 13, the projecting portion 28 is curved to be convex in the thickness direction H, and the thin portion 29 is provided at the base end of the projecting portion 28. ing. As a result, as shown in FIG. 14, the sheet pad 51 can be formed such that the slit portion 15 is curved in the thickness direction H.
In these cases, since the protrusions 28 are formed in various shapes, when the slits 15 are formed in the seat pads 31, 41, 51 by the protrusions 28, the shape of the slits 15 is selected from various shapes. can do.
When the projecting portion 28 is gradually thinned toward the tip end of the projecting portion 28, the tip end of the projecting portion 28 can be positively elastically deformed, and the seat pad 31 is formed on the cavity surface It can be made easier to release from 22.
Further, when the protrusion 28 is gradually thickened toward the distal end of the protrusion 28, the base end of the protrusion 28 is positively elastically deformed to largely elastically deform the entire protrusion 28. As a result, the seat pad 41 can be more easily released from the cavity surface 22.
Furthermore, when the protrusion 28 is curved, it becomes possible to elastically deform the protrusion 28 so that the curvature of the protrusion 28 changes, and the sheet pad 51 can be more easily removed from the cavity surface 22 can do.
The protrusion 28 may extend straight in the thickness direction H. Also, the projecting portion 28 may be provided on the upper mold 24.

  In the above embodiment, the sheet pads 10, 31, 41, 51 are integrally formed of different materials, but the present invention is not limited to this. For example, the seat pads 10, 31, 41, 51 can be integrally formed of the same material.

  In the embodiment described above, the slit portions 15 are separately provided at portions positioned on both sides in the sheet width direction B in the seat pads 10, 31, 41, 51, but the present invention is not limited to this. The slit portion 15 may be provided only on one side of the sheet width direction B. It is possible to change suitably the slit part 15 to the other form provided one or more.

  Although the cushion pad was adopted as seat pad 10, 31, 41, 51 formed of dies 20, 30, 40, 50, the present invention is not limited to this. For example, back pads may be adopted as the seat pads 10, 31, 41, 51, and it is possible to target various applications such as indoor cushions such as chairs and bedding. Furthermore, the seat pads 10, 31, 41, 51 having a placement surface on which a load or the like is placed may be used without being limited to the seating of a person. Furthermore, it may be a mold 20, 30, 40, 50 that forms a foam molded body different from the sheet pad 10, 31, 41, 51.

  In addition, it is possible to replace components in the embodiment with known components as appropriate without departing from the spirit of the present invention, and the above-described modifications may be combined as appropriate.

10, 31, 41, 51 Pads for seat 12 Main body (first foam)
13 side part (second foam)
20, 30, 40, 50 Mold (Production device for foam molding)
Reference Signs List 21 forming die 22 cavity surface 23 cavity 23a first cavity 23b second cavity 24 upper die 25 lower die 28 projecting portion 29 thin portion

Claims (7)

An apparatus for producing a foam molded article, comprising: a cavity defined by a cavity surface of each of the plurality of molds between a plurality of molds; and a protrusion is formed on the cavity surface,
A groove forming portion protruding from the cavity surface is formed in the cavity surface,
The protrusion is formed on the groove forming portion by an elastic body, and a thin portion thinner than other portions of the protrusion is formed in a part or a plurality of the protrusions. An apparatus for producing a foam molded article, characterized in that   The said thin-walled part is arrange | positioned at the base end part of the said protrusion part, The manufacturing apparatus of the foaming molding of Claim 1 characterized by the above-mentioned. An upper mold and a lower mold are provided as the plurality of molds,
The foam-formed body according to claim 1 or 2, wherein the groove forming portion and the projecting portion are formed on the cavity surface of the lower mold and protrude from the lower mold toward the upper mold. Production equipment. The foam molded body includes a first foam and a second foam that are integrally molded,
The groove forming portion and the projecting portion partition the cavity into a first cavity for forming the first foam and a second cavity for forming the second foam;
The apparatus for manufacturing a foam-molded article according to claim 3, wherein the projecting portion gradually extends toward the first cavity side as it goes to the upper mold side.   The apparatus for manufacturing a foam-molded article according to any one of claims 1 to 4, wherein the protrusion is gradually, thin, or thick toward the tip of the protrusion.   The said protrusion part is curving, The manufacturing apparatus of the foam-molded body of any one of Claim 1 to 5 characterized by the above-mentioned. A method for producing a foam molded article, wherein the foam molded article is formed using the apparatus for producing a foam molded article according to any one of claims 1 to 6,
After molding the foam molded body in the cavity, the plurality of molds are opened, and the foam molded body is released from the cavity surface while elastically deforming the projecting portion. How to make the body.

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