JPH01174422A - Manufacture of cushioning foam - Google Patents

Abstract

PURPOSE:To mold a favorable cushioning foam by a method wherein foam molding is done under the condition that a sheet skin lined by a slabstock and a cushioning material are arranged at specified positions in forces. CONSTITUTION:In forces 10 and 11, a slabstock S is faced to the top force side and at the same time a sheet skin C is arranged in the cavity of the bottom force 11 along the surface of the force. Next, the forces are clamped together under the state that the terminal of a cushioning material D consisting of cushioning spring is pinched between the mating surfaces of the respective forces 10 and 11. After clamping, foaming resin E is filled from an inlet 10a into a cavity so as to mold a cushioning foam. As a result, a favorable cushion, in which the slabstock of the sheet skin is impregnated with the proper amount of the foaming resin, and both the foaming resin and the slabstock S are made into an integral body, is obtained. Further, since the terminal of the cushioning material D is impregnated with the foaming resin, the terminal with higher hardness can be produced.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application The present invention relates to a method for manufacturing a cushion foam used as a cushion foam body for a seat, and more specifically, it is applied to foam molding a cushion foam integrally joined to a seat skin. The present invention relates to a method of manufacturing a cushion foam.

Conventional technology In manufacturing this type of cushion form, a seat skin made of a slab material laminated on one side is used, and the end side of the seat skin is sandwiched between the mating surfaces of a mold, and the seat skin is inserted into the cavity of the mold. The cushion foam is placed and then the foamed resin that is filled into the cavity of the mold is foamed to integrally bond and mold the cushion foam with the slab material of the seat skin.

Problems to be Solved by the Invention At this time, if the seal of the mold is loose, there will also be a gap in the mating surface of the mold that holds the end side of the seat skin, allowing air to flow freely through the slab material. A situation arises in which gas generated from the foamed resin used to mold the mold passes through the glabella of the slab material and flows out of the mold. The gas passes through and flows out until the foamed resin gels sufficiently and is no longer impregnated into the layer of the slab material. It becomes highly hard and causes loss of traction properties. In addition, even if the foamed resin does not impregnate the slab material in large quantities, as the gas is discharged outside the mold, a dense layer is generated near the interface with the slab material due to the collapse of the cells. This causes loss of cushioning properties of the seat.

In order to prevent the gas from flowing out, a non-breathable film has traditionally been interposed on the joint surface between the slab material and the cushion foam. Even in the case where the cushion foam is made up of a foam, the air permeability of the cushion foam is blocked, which makes it extremely easy to get stuffy, and the cushion foam and the seat skin become too stuffy.

Peeling may cause cell roughness, and the non-breathable film is expensive, resulting in high costs.

Means for Solving the Problems In the method for manufacturing a cushion form according to the present invention, the end of the seat skin lined with a slab material is separated from the mating surface of the mold, and the seat skin is placed in the cavity of the mold. At the same time, the Mi material of the cushion spring is sandwiched between the mating surfaces of the mold, and the cushion foam is integrally foam-molded with the seat skin and the cushioning material.

Function: In this manufacturing method of cushion foam, the end side of the seat skin is located away from the mating surface of the mold, so even if gas flow occurs from the mating surface, it does not pass through the slab material of the seat skin, resulting in foaming. A large amount of resin is not impregnated into the slab material of the seat skin, and since the cushioning material of the cushion spring is sandwiched between the mating surfaces of the mold, the end of the cushioning material is impregnated with foamed resin, which increases the It becomes possible to form a hard terminal.

Embodiments will now be described with reference to the accompanying drawings.

The manufacturing method of the Kono cushion foam uses a seat skin C laminated with a slab material S on one side, and is applied to integrally foam-molding the cushion foam with a foam resin E such as urethane.

In addition, in this foam molding, the upper mold 10. This is carried out by using a mold equipped with a lower mold 11.

In these molds to, tt, the end side is separated from the mating surface, the slab material S is directed toward the upper mold side, and the sheet skin C is placed in the cavity of the lower mold 11 with the sheet skin C along the mold surface. In addition, after the molds are clamped by sandwiching the &1 shock material of the cushion spring between the mating surfaces of each mold to and it, the foamed resin E is filled into the cavity through the injection port 10a and the cushion foam is foam-molded. You can do it like this.

In foam molding, the seat surface part and the bank part can be formed separately, and when forming the seat surface part, as shown in FIG. Winter version 10.1 of terminals with cushioning material
1 and place it between the mating surfaces of
Just fill it with foamed resin E. When the foamed resin E is foamed after this, a moderate amount of foaming gas flows out from the vent hole tob..., but at least the end of the sheet skin C is not sandwiched between the mating surfaces of the molds to and t''t, so the slab No gas flow passes through the glabella of the material S toward the end of the seat skin C.On the other hand, even if a gas flow occurs from the mating surfaces of the molds to and tt, there is no buffer on this mating surface. Because the ends of the cushioning material are sandwiched, the foamed resin that flows out to some extent as gas is released impregnates the ends of the cushioning material, forming a high-strength product.The seat surface is shown in Figure 2. As shown in FIG. They can be connected and fixed to each other by fixing the seat skin on the side with the C-shaped ring R.

Further, the seat portion and the bank portion can be integrally molded. In this case, as shown in FIG. 4, a seat skin C covering the seat surface is placed in the cavity, and a listing wire W is attached to the rising portion 11a of the lower mold 11 that partitions the seat surface and the bank. It is preferable to arrange the ends of the seat skin C to be hooked. The end of the seat skin C is type 10.11
Since the terminals of m-component materials can be sandwiched and placed on the mating surfaces of the molds to and tt, respectively, gas flows similar to those shown in FIG. 1 can be generated. In the case of this cushion form F2, as shown in Fig. 5.6, the seat skin covering the bank side and the seat skin integrally molded on the cushion form F are connected to the listing wire W using a C-shaped ring R or the like. It becomes possible to fasten and connect.

In addition, since the ends of the cushioning material are made of foamed resin E with high strength, they can be securely fixed to the seat frame B.

Effects of the Invention As described above, according to the manufacturing method of the cushion foam according to the present invention, foamed resin can be appropriately impregnated into the slab material of the seat skin and integrated, so peeling between the eyebrows does not occur and there is no problem with wrinkles. This allows the cushion foam to be foam-molded integrally with the seat skin while retaining good weather resistance, and also allows the ends of the cushioning material to be securely attached to the seat frame.

[Brief explanation of the drawing]

FIG. 1 is an explanatory diagram showing a method for manufacturing a cushion form according to an embodiment of the present invention, FIG. 2 is an explanatory diagram showing a mounting structure of the cushion foam, and FIG. FIG. 4 is an explanatory view showing a method of manufacturing a cushion form according to another embodiment, and FIGS. 5 and 6 are explanatory views showing an assembly structure of the same cushion form. 10.11: Mold, S varnish slab material, C; sheet skin, E
: Foamed resin, D: Cushioning material.

Claims (1)

[Claims] The end of the seat skin lined with slab material is separated from the mating surface of the mold, and the seat skin is placed in the cavity of the mold, and the cushioning material of the cushion spring is inserted into the mating surface of the mold to create a cushion. A method for manufacturing a cushion foam, characterized in that the foam is integrally formed with a seat skin and a cushioning material.