JPH025641B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a cushion body made of a foam, particularly a cushion body whose surface is integrally covered with a surface material such as leather, and in which a bead is provided along the ridgeline of the cushion body. Regarding.

This type of cushion body is intended to have a beaded edge along its ridgeline to make the ridgeline stand out and give it a design accent. A built-in surfacing material is used. In the figure, numerals 1 and 1' are facing materials made of leather, cloth, etc., and a seam allowance 2' of a welt 2 is sewn between the ends of both facing materials 1 and 1'. The bead 2 includes a bead core 3 such as a polyvinyl chloride pipe. The aforementioned cushion body was manufactured in the following manner using the beaded surface material shown in FIG. 1 above.

In FIG. 2a, 4 to 6 are molds for the cushion body, 4 is the upper mold, 5 is the middle mold, and 6 is the lower mold. The upper mold 4 has an inner wall surface corresponding to the top surface shape of the cushion body, the middle mold 5 has an inner wall surface corresponding to the side surface shape, and the lower mold 6 has an inner wall surface corresponding to the bottom surface shape. Further, the boundary between the upper mold 4 and the middle mold 5 exactly corresponds to the ridgeline of the cushion body. and,
As shown, the surface material 1 of FIG. 1 is placed on the inner wall surface of the upper mold 4 with the bead 2 extending outside the mold, and the surface material 1' extends outside the mold as a gusset. Ru. Next, a foam raw material such as a polyurethane foam stock solution is injected onto the lower mold 6, the mold is closed and foam molding is performed, and when this is cured and demolded, the surface becomes as shown in Figure 2b. A foamed molded body 7 integrated with the material 1 is obtained. Thereafter, the desired cushion body is obtained by adhering the surface materials 1', 1' of the gusset portions to the side and back surfaces of the foamed molded body 7.

In addition, as shown in FIG. 3, the upper mold 4 of FIG.
There is also a method in which the lower mold 6 is used as the lower mold and the lower mold 6 is used as the upper mold. This method can be said to be a rather common method since it is easier to arrange the surface material 1. However, in this case, the foam stock solution is injected directly onto the surface material 1, so if, for example, a soft polyurethane foam sheet is used as the surface material, the foam stock solution will be stronger than the surface material 1. A problem arises in that the surface material 1 hardens and changes in quality due to impregnation. In such a case, the method shown in FIG. 2b is used, which is somewhat inconvenient when disposing the surface material 1, but can effectively suppress impregnation into the surface material 1.

By the way, in any case, in the conventional manufacturing method, the bead edges 2, 2 were placed outside the mold and the surface material 1 was disposed, which caused the following problems.

First, in the molded product shown in FIG. 2b obtained by demolding, the bead edges 2, 2 do not come into close contact with the foamed molded product 7;
It is spaced apart from the surface by at least the thickness of the mold. For this reason, the gusset 1' of the surface material
When gluing 1', if you try to hold the bead edges 2, 2 at the ridgeline position, the bead edges 2, 2 will be glued together as shown in Figure 4a.
becomes protruding from the surface of the cushion body,
Also, if you try to make the bead edges 2 and 2 stick together, see Figure 4b.
As shown in the figure, the positions of the bead edges 2, 2 are shifted downward from the ridge line, and in either case, there is a problem that the desired design effect cannot be obtained.

Second, it is very difficult to uniformly arrange the surface material 1 with its bead 2 correctly aligned with the outer edge of the mold, and the surface material 1 may be partially wrinkled and uneven. It's easy to happen. In particular, when the surface material 1 is disposed on the upper mold 4 as shown in FIG. 2a, the surface material tends to be misaligned and become non-uniform when the mold is closed as shown. If this happens, wrinkles will be formed in the surface material 1 along the ridge lines during foam molding. In this case, since the surface material 1 is integrated with the foamed molded product 7 while still wrinkled, it is impossible to remove the wrinkles later, and this poses a problem of causing defective products. Ta.

The present invention has been made in view of the above circumstances, and in particular, when manufacturing a cushion body having a beaded edge on the ridge line by disposing a surface material with a beaded edge on an upper mold, the beaded edge is attached to the cushion body. To provide a method for manufacturing a cushion body that can prevent the cushion body from shifting from the ridgeline position or lifting up, and can also prevent the formation of wrinkles on the surface material.

That is, the present invention uses a mold including an upper mold having an inner wall surface corresponding to the shape of the top surface of the cushion body and divided at a portion corresponding to the ridge line of the cushion body. After disposing the surface material to which has been attached in advance on the inner wall surface of the upper mold so that the gusset extends to the outside of the mold, the foam raw material is filled into the mold to remove the surface material. In the method of manufacturing a cushion body, the mold includes a presser frame that presses the surface material by contacting the open end surface of the upper mold, and the presser frame mold and the upper mold are connected together. Manufacturing a cushion body characterized in that a groove for storing the bead is provided in the mating part, the bead is fitted into the groove, the surface material is arranged, and this is fixed by pressing with the presser frame mold. It's a method.

Embodiments of the present invention will be described below with reference to FIGS. 5 and 6.

Embodiment (i) As shown in FIG. 5a, an upper mold 11 having an inner wall surface corresponding to the top surface of the cushion body, a middle mold 12 having an inner wall surface corresponding to the side surface, and a lower mold having an inner wall surface corresponding to the bottom surface. In addition to 13, upper mold 11
A mold including a presser frame 14 which is interposed between the upper mold 11 and the middle mold 12 and comes into contact with the open end surface of the upper mold 11 is prepared. The mating portion between the upper mold 11 and the presser frame mold 14 corresponds to the ridgeline portion of the cushion body.
A groove is formed in this mating part to accommodate the bead provided on the surface material, and the surface material 1 shown in FIG. 1 is placed inside the upper mold 11 with the bead 2 fitted into the groove. Place it on the wall. The gusset portions 1', 1' extend from between the upper mold 11 and the presser frame mold 14 to the outside of the mold. The presser frame type 14 can be pressed and fixed to the end surface of the upper mold 11 before the mold is closed, and the surface material 1 disposed on the upper mold 11 as described above can be pressed and fixed to the end surface of the upper mold 11 before the mold is closed. It is first fixed with this presser frame mold 14 so that it does not shift.

6a to 6c are enlarged cross-sectional views showing the mating portion of the upper die 11 and the presser frame die 14 in FIG. 5a, and any of these embodiments may be used. In FIG. 6a, a groove is formed on the presser frame mold 14 side, and in FIG. 6b, a groove is formed on the upper mold 11 side. In FIG. 6c, grooves are formed across both sides.

(ii) After arranging the surface material as shown in FIG. 5a, a polyurethane foam stock solution is poured onto the lower mold 13 and the mold is closed. Subsequently, after foaming and curing, demolding is performed to obtain a polyurethane foam 15 to which the surface material 1 is integrally bonded, as shown in FIG. 5b.

At this time, foam molding is performed with the bead 2 held close to the molding chamber, so in the resulting foam molded product shown in FIG. In close contact. On the other hand,
Since the bead 2 is fitted into the groove formed in the upper mold 11 or the presser frame mold 14, the surface material 1 can be reliably
can be uniformly arranged, and since it is fixed by the presser frame mold 14, no displacement of the surface material 1 occurs. Therefore, almost no wrinkles are formed in the surface material 1 in the foam molded product shown in FIG. 5b.

(iii) After that, the gussets 1', 1' of the surface material in the foam molded product shown in FIG.
By rolling it around the side and back surfaces of the cushion and gluing it, a cushion body having beaded edges 2, 2 in close contact along the ridgeline can be obtained as shown in FIG. 5c.

In the above embodiment, a mold in which the middle mold 12 and the lower mold 13 are separated is used, but it is also possible to use a mold in which the middle mold 12 and the lower mold 13 are integrated.

As described in detail above, according to the present invention, it is possible to manufacture a cushion body in which the bead edges are properly adhered to along the ridgeline of the cushion body, and also to prevent the formation of wrinkles on the surface material. It is something that you have.

[Brief explanation of drawings]

Fig. 1 is a sectional view showing a surface material provided with a beaded edge, Figs. 2a, b and 3 are sectional views for explaining a conventional manufacturing method of a cushion body, and Figs. Cross-sectional views for explaining problems in conventional manufacturing methods, FIGS. 5 a-c and 6 a-
c is a sectional view for explaining an embodiment of the present invention. 1...Surface material, 1'...Surface material (gusset part), 2...Belt edge, 11...Upper mold, 12...Medium mold, 13...Lower mold, 14
...Presser frame type, 15...Polyurethane foam.

Claims (1)

[Claims] 1 Using a mold including an upper mold having an inner wall surface corresponding to the shape of the top surface of the cushion body and divided at a portion corresponding to the ridgeline of the cushion body, a bead along the ridgeline portion of the cushion body is attached in advance. After arranging the surface material on the inner wall surface of the upper mold so that its gusset extends to the outside of the mold,
In a method for manufacturing a cushion body in which a foam raw material is filled into a mold and foam-molded integrally with the surface material, a presser frame mold that presses the surface material by contacting an open end surface of the upper mold is placed in the mold mold. At the same time, a groove for storing the bead is provided at the mating part of the presser frame mold and the upper mold, the bead is fitted into this groove and the surface material is disposed, and the surface material is placed in the presser frame. A method of manufacturing a cushion body, which is characterized by press-fixing with a mold.