JPH04173306A - Manufacturing device for surface layer material for seat - Google Patents

Abstract

PURPOSE:To foam-mold a pad material integrally on a surface material in the simple and proper state by injecting a foaming resin material into a cavity in the state that the peripheral face and back face of skin material fed outside the cavity are stored in a space sealed by a sealing material. CONSTITUTION:A front face section 13 of a skin material 10 in the turned-over state is placed in a manner of covering an upper wall 13 of a bottom force 1, and a core mold 9 is loaded on an upper wall 6 of a top force 2, and then mold closing is performed to form a cavity K by the upper wall 3 of the bottom force 1 and the upper wall 6 of the top force 2. A front face 13 of the skin material 10 is brought into contact with the upper wall 3 of the bottom force 1 by a step section 22 of the top force 2 and the surface material 10 is engated with, and a folded peripheral face 14 of the skin material 10 and a back face 15 are stored in a space 17 formed by a peripheral wall 4 and a base 5 of the bottom force 1 and a side wall 7 of the top force 2, and the space 17 is sealed by a sealing material 18. A foaming resin material is injected from a feeding tube 24 into the cavity K through a nozzle 8. A pad material 25 is foam-molded integrally on the front face 13 of the surface material 10.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a seat constituting a vehicle seat or a sofa of furniture, etc., which has a headrest integrally provided at the upper end of the backrest. The present invention relates to an apparatus for producing a surface layer material for a sheet, which is installed on the surface of a sheet.

[Conventional technology]

The above-mentioned surface layer material for a sheet is composed of a skin material such as a cloth material, a skin material made of a wadding material such as foamed polyurethane lined on the back surface, and a pad material made of an am11 foam material. As shown in , there is a lower mold to which the skin material covering the backrest and headrest of the seat is attached, an upper mold that is movable up and down above the lower mold of the mouth, and the upper mold! The padding material is formed by integrally foam-molding the padding material on the inner surface of the skin material using a manufacturing device equipped with an injection mechanism for injecting foamed resin material into a cavity formed in the space between the skin material and the lower mold.

(Problems to be Solved by the Invention) In the conventional manufacturing apparatus configured as described above, the upper part of the skin material covering the headrest part of the seat, that is, the undercut molding surface to which the bag-shaped undercut part is attached, is the lower mold. Since the undercut is formed in a recessed position, there is a problem in that it is difficult to properly attach the undercut of the skin material along this undercut molding surface. A core mold for forming a space for inserting the frame material in the headrest portion of the seat is disposed between the upper mold and the lower mold, and the core mold is movable vertically but not horizontally. support means for supporting in a state;
By providing a positioning means for regulating the upward movement position of the core mold and a holding means for holding the core mold in the upward movement position, the core mold can be inserted into the undercut molding surface in an appropriate state and stopped. However, there is a problem in that the structure of the foam mold is complicated.

The present invention has been made in order to solve the above-mentioned problems, and it is possible to precisely position and attach the skin material to the foam mold with a modular structure, and also to place the frame material in the appropriate position of the headrest part. An object of the present invention is to provide an apparatus for manufacturing a sheet skin material that can easily form an opening for insertion.

[Means to solve the problem]

The present invention provides an inner surface of a skin material that includes a front surface that covers the front surface of a seat back and a headrest, a peripheral surface that covers the side and bottom surfaces of the front rest, and a back surface that covers the back of the headrest. , an apparatus for manufacturing a sheet surface material that integrally foam-molds a pad material, which comprises a lower mold forming a lower wall of a cavity for foam molding, and an upper mold forming an upper wall of the cavity. , the lower mold is provided with an upper wall portion on which the front surface of the skin material is placed upside down, a side wall portion protruding from the lower surface of the upper wall portion, and a substrate disposed at the lower end of the upper wall portion; The mold includes a stepped portion that presses the peripheral portion of the front surface portion to the upper surface portion of the lower mold in the mold closed state, and a fgW of the lower mold.
A core that surrounds the outer periphery of the flJ and constitutes an empty maB in which the periphery W1 and the back surface of the skin material are accommodated, and forms an opening for inserting the frame material in the headrest part of the seat. The mold is detachably mounted, and a sealing material for sealing the above-mentioned 9111 portion is provided between the substrate of the lower mold and a portion of the circumference of the upper mold.

C action] According to the present invention having the above configuration, the upper part of the lower mold! When the upper mold is lowered and closed with the front part of the skin material in an upside-down state attached to the part, the peripheral edge of the front part is sandwiched between the stepped part of the upper mold and the upper wall W3ζ of the lower mold, and the skin material is fixed in position, and the peripheral surface and back surface of the skin material are
It is housed in a space formed by the peripheral wall and substrate of the lower mold and the side wall of the upper mold, and the space is sealed with a sealing material. In addition, with the core mold attached to the upper wall of the upper mold, foam 1 is placed inside the cavity.
By filling the N resin material, an opening for frame insertion is formed in the headrest portion of the seat surface material.

〔Example〕

FIG. 1 shows an embodiment of the manufacturing apparatus for sheet surface material according to the present invention, which comprises a lower mold 1 forming a cavity K for foam molding, and an upper mold 2. is flattering. The lower mold 1 includes an upper wall 3 forming the lower surface of the cavity, a side wall 4 protruding from the lower surface of the upper wall 3, and a substrate 5 disposed below the side wall 4. It is equipped with The upper mold 2 has an upper wall portion 6 constituting the upper surface of the cavity, and a periphery 911.7 projecting downward from the peripheral edge of the upper wall portion 6. Further, a nozzle 8 that serves as an injection pipe for the foamed resin material is attached to the upper wall portion 6 of the upper mold 2, and a core mold 9 is provided to form a space for inserting the frame material in the headrest portion of the seat. It is attached removably.

As shown in FIG. 2, the skin material 10 attached to the lower mold 1 and the upper mold 2 includes a front surface portion 13 that covers the front surfaces of the backrest portion 11 and the headrest portion 12 of the seat, and the side surfaces of the backrest portion 11 and the front surface of the headrest portion 12. It includes a peripheral surface part 14 that covers the bottom surface, and a back surface part 15 that covers the back surface of the headrest part 12.
5 are connected by means such as sewing or gluing. The skin material 10 is usually made of a fabric such as moquette or synthetic leather, and a wadding made of foamed polyurethane, foamed polyethylene, foamed polypropylene, foamed ABS, etc., which is fixed to the back surface by means such as frame lamination or adhesion. It is made up of materials.

The skin material 10 has a peripheral surface portion 14 and a back surface portion 15.
is folded back in the direction shown by the arrow in FIG. 2 using the connection part 16 with the front part 13 as a fulcrum, and the front and back sides are reversed, and as shown in FIG. configured to be positioned. That is, the upper wall portion 3 of the lower mold 1 is attached to the skin material 1 which is in an inverted state.
A positioning portion 3a is formed in a size and shape corresponding to the front surface portion 13 of 0, and a positioning portion 3a consisting of a flat surface with a predetermined width is formed at the periphery of the upper wall portion 3. And above! Part 3
By attaching the skin material 10 so as to cover the surface material 10, the connecting portion 16 of the skin material 10 is positioned by coming into contact with the outer periphery of the positioning portion 3a.

As shown in FIG. 3, the peripheral wall portion 7 of the upper mold 2 is disposed so as to surround the side wall portion 4 of the lower mold 1 in the mold closed state, and its lower end portion is located above the substrate 5 of the lower mold 1. Its length is set so that it comes into contact with the sealing member 18 installed in the
This peripheral wall 7, the side wall part 4 of the lower mold 1, and the substrate 5 constitute a space part 17 in which the peripheral part 14 and the back part 15 of the skin material 10 are accommodated. Above upper mold 2
The nozzle 8 provided on the upper wall portion 6 is bent such that a lower portion 8a is inclined at a predetermined angle. Also, upper mold 2
The core mold 9 attached to the upper mold 2 consists of a core body 19 to be inserted into the headrest part of the cavity, and a base end part 20 to be installed in the insertion hole 9a formed in the upper wall part 6 of the upper mold 2. A seal member 21 is disposed between the base end portion 20 and the outer surface of the upper wall portion 6.

Also, the upper wall portion 6 of the upper mold 2 and the circumference W! The positioning al1 formed on the peripheral edge of the upper wall portion 3 of the lower mold 1 is located between the
A step 8I122 facing 3a is formed, and this step 22
The periphery of the front part 13 of the skin material 10 is placed above! 1
It is designed to be pressed onto 1113. That is,
In the closed state of the lower mold 1 and upper mold 2, stage 8I of the upper mold 2! 22 and the positioning f133a of the lower mold 1, there is a gap smaller than the thickness of the skin material 10, for example 1
The step 11122 is arranged so that an rR gap of about mm is formed.
is installed, and the above-mentioned front ali 13 is
It is configured so that the peripheral edge of the mold is fixed to the upper surface of the positioning part 3a of the lower mold 1 by pressing downward. In addition, the step portion 2
As shown in FIG. 4, a covering part 23 is formed on the inner peripheral part of the mold 2, protruding inward from the positioning part 3a of the lower mold 1 and covering the upper surface of the skin material 10.

When manufacturing a sheet surface material using the manufacturing apparatus configured as described above, first, as shown in FIG. 13, and the skin material 10 is positioned by bringing the front part 13 of the skin material 10, the connecting part 16 between the peripheral surface ali 14 and the back surface part 15 into contact with the peripheral part of the positioning part 3a. Attach it to the lower mold 1.

Then, the core mold 9 is placed on the upper wall portion 6 of the upper mold 2. In this state, as shown in FIG. 3, the upper mold 2 is lowered onto the lower mold 1 to close the mold. As a result, the upper part W13 of the lower mold 1 and the upper mold 2
A cavity K for foam molding is formed by the upper wall 6 of . Further, the front part 13 of the skin material 10 is pressed onto the upper wall part 3 of the lower mold 1 by the stepped part 22 of the upper mold 2, and the skin material 10 is locked, and the skin material is folded back as described above. The peripheral surface part 14 and back surface part 15 of 10 are housed in a space 17 formed by the peripheral wall 4 and substrate 5 of the lower mold 1 and the side wall 7 of the upper mold 2, and this space 17 is It will be sealed by the sealing material 18.

Next, a supply pipe 24 communicating with a foam molding machine (not shown) is connected to the nozzle 8 of the upper mold 2, and a foamed resin material for molding the pad material is supplied from the supply pipe 24 into the cavity through the nozzle 8. inject. During this injection, the course of the foamed resin material changes at the bent portion of the nozzle 8, and the flow rate decreases as the flow resistance increases, so that the foamed resin material is supplied into the cavity in a diffused state. The pad material 25 is integrally foam-molded on the front surface portion 13 of the skin material 10 using the foamed resin material supplied in this manner. In other words, a portion of the foamed resin material is impregnated into the wadding material of the front section 13, so that the pad material 25 is foam-molded while being integrally joined to the front section 13.

After foam-molding the pad material 25 in this way, the upper mold 2
The core mold 9 is removed from the upper wall part 6, and then the upper mold 2 is raised to release the skin material 10 from the lower mold 1 and the upper mold 2, and the peripheral surface part 14 and back surface part 15 of the skin material 10 are removed. By folding it back to its original state and applying it to the circumferential surface of the pad material 25, a seat surface material having an opening 26 for inserting the frame in the headrest portion 12 is formed, as shown in FIG. Then, a vehicle seat or the like is constructed by attaching the above-mentioned seat surface material to a seat frame or the like (not shown).

As described above, the skin material 1o in an upside-down state is attached so as to cover the upper wall portion 3 of the lower mold 1, and the skin material Since the configuration is such that the ten connecting portions 16 are brought into contact with each other for positioning,
The skin material 10 can be easily and accurately positioned and installed on the lower mold 1. When the mold is closed, the peripheral part of the front surface part 13 is brought into pressure contact with the upper wall part 3 of the lower mold 1 by the step part 22 provided on the upper mold 2 of the foam molding mold, so that the surface layer is removed at the same time as the mold closing operation. The material 10 is fixed to the lower mold 1, and the foamed resin material for molding the pad material can be injected while the skin material 10 is prevented from shifting.

Further, when the mold is closed, the side wall 4 and substrate 5 of the lower mold 1 and the peripheral wall 7 of the upper mold 2 cause the peripheral surface 1 of the skin material 10 to
4 and the back surface 15, and the space 17 is sealed with a sealing material 18, so that the cavity is filled with foam m.
When injecting 1 liter of material, the internal pressure of the space 17 increases, thereby effectively preventing the foamed resin material from flowing into the space 17. Therefore, it is possible to prevent the peripheral surface section 14 and the back surface section 15 from being soiled by the foamed resin material that has flowed into the space section 17. In addition, since the pressure inside the cavity 17 rises quickly in response to the rise in pressure in the space 17, it is possible to prevent the foamed resin material from being excessively supplied.
It is possible to prevent the amount of foamed resin material impregnated into the wadding material of the front surface part 13 located inside the cavity from increasing, thereby preventing the hardness of the skin material 10 from becoming too high.

In addition, since the core mold 9 is removably attached to the insertion hole 9a provided in the upper wall portion 6 of the upper mold 2, the pad material 25 is inserted with the core mold 9 inserted into the insertion hole 9a. The headrest part 1 of the surface layer material for the seat is made by foam molding.
The opening 26 for inserting the frame can be easily formed at the appropriate position of 2. In addition, by pulling the base end portion 20 outward, the core mold 9 can be easily removed from the upper wall portion 6 of the upper mold 2, which facilitates the m-shape work of the sheet surface material. be able to.

In the above embodiment, the lower part 8 of the nozzle 8 provided on the upper die 2
a is tilted at a predetermined angle, the course of the foamed resin material is changed at this bent portion, and the flow rate is reduced, so that the foamed resin material is supplied into the cavity in a diffused state. , it is possible to prevent the foamed resin material from being sprayed concentratedly at one location on the skin material 10. Therefore, the advantage is that the foamed resin material can be evenly sprayed over substantially the entire surface of the wadding material located inside the cavity, and the amount of impregnation of the foamed resin material can be made uniform, thereby optimizing the hardness of the skin material 10. There is.

Further, in the above embodiment, a covering part 23 that protrudes inward of the positioning part 3a of the lower mold 1 is provided on the inner peripheral part of the stepped part 22 of the upper mold 2, and the covered part 23 protrudes inward of the positioning part 3a of the lower mold 1. Since the cavity is configured to be filled with a foamed resin material for forming a pad material while covering the upper surface of the skin material 10 located nearby, the skin material sandwiched between the stepped portion 22 and the positioning portion 3a In the vicinity of the held part 27 of 10,
It is possible to prevent the foamed resin material from being impregnated, thereby preventing molding defects from occurring. That is, it is possible to omit the covering part 23 and arrange the inner end of the step part 22 at the same position as the positioning part 3a of the lower mold 1, as shown in FIG. , the step part 2
The impregnated part protrudes outward by infiltrating the upper part of the raised part 28 formed in the part adjacent to the held part 27 of the skin material 10 held by the positioning part 2 and the positioning part 3a. 29 will be formed. Therefore, as shown in FIG. 8 after molding, when the peripheral surface part 14 of the skin material 10 is inverted so as to follow the peripheral surface of the pad material 25, the existence of the impregnated part 29 causes the skin material 10 to
A bulge 3O is formed on the surface of the skin, impairing its appearance, and the skin material 10 feels uncomfortable in this area.

On the other hand, when the covering part 23 provided on the stepped part 22 of the upper mold 2 is configured to cover the part of the skin material adjacent to the clamped part 27 as described above, the part of the skin material adjacent to the clamped part 27 is Since the formation of a raised portion can be prevented, it is possible to prevent the formation of an outwardly protruding impregnated portion of the foamed resin material in the vicinity of the sandwiched portion 27 of the skin material 10. . Therefore, the above-mentioned bulges are not formed on the surface of the skin material 10, and as shown in FIG. 5, the surface of the skin material 10 can be appropriately curved to provide an excellent appearance. , it is possible to prevent the above-mentioned discomfort from occurring.

In the above embodiment, an example was explained in which the skin material 10 was composed of a skin made of cloth or the like and a wadding material. The skin material may be composed of a film material such as a melt film or a coating layer made of polyethylene or polypropylene. In addition, a backing material made of non-woven fabric, urethane film, polyethylene film, polypropylene film, nylon half, cotton cloth, etc. may be provided on the back side of the wadding material. In this case, the amount of impregnation of the foamed resin material by the backing material Since the hardness of the skin material 10 can be adjusted, there is an advantage that the hardness of the skin material 10 can be set more appropriately.

[Effects of the Invention] As explained above, the present invention allows the front surface of the skin material to be easily and accurately positioned and fixed to the upper wall of the lower mold, and also to prevent the skin material from being led out of the cavity. The foamed resin material is injected into the cavity while the peripheral surface and the back surface are housed in the space sealed by the sealing material, so it is possible to easily and properly foam the padding material on one skin material. Can be molded. In addition, since the core mold is removably installed on the upper wall of the upper mold, it has advantages such as being able to form an opening for inserting the frame in the headrest part without complicating the structure of the foam molding mold. There is.

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view showing an embodiment of the manufacturing apparatus for sheet surface material according to the present invention, FIG. 2 is a perspective view showing the overall structure of the skin material, and FIG. 3 is a cross-sectional view showing the molded state of the pad material. , Fig. 4 is a partially enlarged view of Fig. 3, Fig. 5 is a partially enlarged view of Fig. 6,
FIG. 6 is a sectional view showing the structure of the sheet skin material, FIG. 7 is a view corresponding to FIG. 4 showing another embodiment of the present invention, and FIG.
FIG. 5 is a view corresponding to FIG. 5 showing a sheet surface material manufactured by the manufacturing apparatus shown in the figure. 1... Lower mold, 2... Upper mold, 3... Upper wall of lower mold,
4... Side wall portion of the lower mold, 5... Substrate of the lower mold, 6...
Upper wall portion of upper mold, 7... Circumference wtis of upper mold, 10...
Skin material, 1...backrest part, 12...headrest part, 13...front part, 14...peripheral part, 15...
・Back part, 17... Space part, 18... Seal material, 2
2... Danbe, K... Capitei. Figure 3

Claims (1)

[Claims] 1. Pad material is applied to the inner surface of a skin material consisting of a front surface that covers the front surface of the seat back and headrest, a peripheral surface that covers the side and bottom surfaces of the backrest, and a back surface that covers the back of the headrest. An apparatus for manufacturing a surface layer material for a sheet that integrally performs foam molding, comprising: a lower mold forming a lower wall of a cavity for foam molding; and an upper mold forming an upper wall of the cavity; a top wall portion on which the front surface of the skin material is placed upside down; a side wall portion protruding from the bottom surface of the top wall portion; and a substrate disposed at the bottom end of the top wall portion;
The upper mold has a step part that presses the peripheral part of the front part to the upper part of the lower mold when the mold is closed, and a step part that surrounds the outer periphery of the side wall part of the lower mold and accommodates the peripheral wall part and the back part of the skin material. In addition, a core mold forming an opening for inserting the frame material is removably attached to the headrest portion of the seat, and a base plate of the lower mold and a peripheral wall of the upper mold are provided. 1. An apparatus for manufacturing a sheet surface material, characterized in that a sealing material for sealing the space is provided between the space and the space.