JPH0434439B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application The present invention provides a molding process by adhering the skin to a cushion body such as a urethane mold, which is breathable and provides a comfortable riding experience without losing the original soft feel of the skin. Used in the technical field of seat bodies.

BACKGROUND TECHNOLOGY The conventional method for producing a molded seat body is to heat a skin fixed to the outer periphery of the lower mold between an upper mold and a lower mold, each having a mold surface having the same shape as the surface of the cushion body of the seat body.
The upper mold is pressed to form the surface shape of the cushion body, and then the upper mold is lifted once, and the molded skin surface and/or the surface of the cushion body such as a skinless mold or slab material are formed. The manufacturing method involved applying an adhesive with a spray gun or brush, then matching the molded shape of the skin with the shape of the cushion body, pressing the cushion body with an upper mold, and bonding the skin and the cushion body.

Problems to be Solved by the Invention The conventional manufacturing method of the seat body as described above has the following drawbacks.

a) When applying the adhesive with a spray gun or brush, it is difficult to apply the adhesive evenly, and if there is too much adhesive, stains will appear on the surface and the appearance will be poor. It becomes partially hard and also impedes breathability. Alternatively, if the amount applied is too small, the adhesive strength will be insufficient and the epidermis will peel off.

b. The cost of equipment for spraying the adhesive and sanitary measures to prevent air pollution from spraying is considerable. Also, it takes a lot of man-hours from spraying to adhesion.

c Adhesives, such as urethane adhesives, take 45 minutes to complete adhesion when the outside temperature is around 18℃.
However, at 5°C it takes about 60 seconds, so it costs even more money to take measures against low temperatures.

d Furthermore, if the adhesive is not bonded within a predetermined time after spraying, the bonding force will be weak or the bonding will not be possible.

e Conventionally, products using a machine-sewn trim cover with a three-dimensional appearance of unevenness using a skin with little elongation are made by cutting a flat surface of the skin from a three-dimensional shape in advance and sewing it three-dimensionally with a sewing machine.
These operations and furthermore, bonding the trim cover to the surface of the same three-dimensional urethane mold require skill and a large number of man-hours.

Means for Solving the Problems The present invention employs the following means to solve the above-mentioned problems. That is, on the surface of a cushion body made of a skinless urethane mold or a cut-molded urethane slab, a skin heat-molded with an upper mold and a lower mold having mold surfaces of the same shape as this surface is placed on the surface of the cushion body. In a manufacturing method of a seat body characterized in that the cushion body and the air in its internal bubbles are heated to a high temperature in advance,
After that, it is characterized by adhesive molding. In addition, the present invention provides a skinless urethane mold or a cut-molded urethane slab cushion body, and a highly elongated skin that is not heat-molded is interposed between the skin and the above-mentioned cushion body. The method of manufacturing a seat body is characterized in that the cushion body and the air in its internal bubbles are heated to a high temperature in advance, and then adhesive molding is carried out.

Effect: According to the above-mentioned means, adhesion between the skin and the cushion body such as the urethane mold is reliable and easy, and
It is possible to obtain a seat body with no uneven adhesion, a beautiful appearance, and a good feeling.

EXAMPLE Next, a method for manufacturing a seat body of the present invention will be explained in order of steps with reference to the accompanying drawings.

In the first embodiment, in a process shown in FIG. 1, the skin 1 is turned over and attached to the outer periphery of a lower mold 6, which has a mold surface on the upper surface having a shape opposite to the outer shape of the sheet.

In the next step shown in FIG. 2, the skin 1 attached to the lower mold 6 is heated by the heater 7 placed close to the upper part of the lower mold 6.

In the step shown in FIG. 3, the skin 1 heated in the above step is compressed by an upper mold 8 having an opposite shape to the lower mold 6, that is, the same shape as the outer shape of the sheet, to form it into the desired shape of the sheet.

In the process shown in FIG. 4, the skin 1 formed in this manner remains attached to the lower mold 6, and the fusion cloth 2 is placed on the required portion thereof.

Next, in the step shown in FIG. 5, the upper mold 8A is aligned over the fusing cloth 2, pressurized, and heated. Then, the fusing cloth 2 is deformed and molded. The heaters 9 inside the lower mold 6 and the upper mold 8A are used to heat and shape the fusing cloth 2. epidermis 1
The temperature at which the fusible cloth 2 is heated and formed is lower than the temperature at which it is heated and formed by the heater 7.

Next, as shown in Fig. 7, the urethane mold 3
Preheat. FIG. 7 shows the cushion body heating compressor 12. As shown in FIG. Reference numeral 13 designates a sealed box, on the lower side of which is placed a rigid porous pedestal 16 that has a shape that roughly contacts the mountain portion of the cushion body 3 and has many small holes or is porous. 16
Place the cushion body 3 on top of the positioning pin 11.
The pressing mold 10 is placed together through the compression shaft 1.
4, the cushion body 3 can be compressed.

Since the compressed cushion body is a skinless, open-cell urethane mold or a cut-molded urethane slab, by being crushed in this way, the air in the cells is discharged from the air discharge hole 17. Next, when the compression shaft 14 is raised upward while taking in high-temperature air from the high-temperature air intake port 17A, the cushion body 3 returns to its original shape due to its own elasticity. invade inside. When this operation is repeated, the cushion body 3 is filled with high-temperature air, and the temperature of the cushion body 3 itself increases. Next, the cushion body 3 is taken out from the box 13 (the take-out opening is not shown) and immediately transferred to the process shown in FIG. In this step, remove the upper mold 8A,
A cushion body 3 made of a skinless urethane mold or a cut-molded urethane slab and a positioning pin 1
The cushion body 3 is compressed by aligning the press die 10 and the lower die 6 via the press die 1 and compressing the press die 10. The cushion body 3 has a high temperature and contains high-temperature air, so when the press die 10 is compressed, it comes into contact with the fusible cloth 2 and the fusible cloth is heated. The fusing cloth 2 is deformed and melted to fuse the outer skin 1 and the cushion body 3 together.

This is effective as a measure against the low temperature of the convex portion 6A when heated by the heater 9 in FIG. 6, and improves the adhesion of the convex portion (the concave portion in the product).
Alternatively, the heating of the heaters 9 in the lower mold 6 and upper mold 8A is promoted. Alternatively, the heater 9 may be omitted depending on the temperature.

FIG. 8 is a sectional view of the sheet taken out from the mold after completion of the process shown in FIG. 6 and inverted. The fusing fabric 2 actually melts into the skin 1 and the cushion body 3 to form a thin layer. In this case, air permeability is provided by melting or tearing the fusing cloth.

Some examples of processing orders different from the above-mentioned process order will be described below.

a Figure 1, Figure 2, Figure 4, Figure 3A, Figure 7
The machining order is as shown in Fig. 6. In this case, the second
While the heat of the skin 1 is maintained in the process shown in the figure, the fusible fabric 2 is attached in the process shown in FIG. 4, and the skin 1 and the fusible fabric 2 are simultaneously molded in the process shown in FIG. 3A. Next, in the process shown in FIG. 6, the fusing cloth 2 is melted to bond the outer skin 1 and the cushion body 3.

b Figure 1, Figure 2, Figure 3, Figure 4, Figure 7,
The processing order is as shown in Figure 6. In this case, there is little unevenness on the surface of the cushion body, and there is no need to form the fused fabric 2 in the process shown in FIG. 3A, and the fused fabric 2 is formed and melted at once in the process shown in FIG. 6. .

c Next, although not shown, the fusing cloth 2 is also superimposed on the skin 1 in the process shown in FIG. Next, without heat-forming the skin 1 and the fusion fabric 2, the seventh
Proceeding to the steps shown in Figures 1 and 6, the cushion body 3 is placed and compression molded using a press die 10, and the fusing cloth 2 is melted to bond the outer skin 1 and the cushion body 3.
This occurs when the elongation of the outer skin 1 and the elongation of the fused fabric 2 are large, or when the surface of the cushion body 3 has few irregularities and the outer skin 1 and the fused fabric 2 can be formed with the pressure of the press die 10. be.

d In addition to the above-described embodiments, it is possible to adopt a process order in which the order of the above-mentioned figures is changed depending on the materials and shapes of the skin 1 and the fusing cloth 2, and the shape to be molded.

Next, a product manufactured by the manufacturing method of the present invention will be explained.

8 to 10 show examples of the product.

The epidermis 1 is a single, stretchable epidermis. (If the skin has a large elongation, it may not be necessary to heat-form the upper and lower molds.) However, although necessary parts are omitted from the illustration, two different skins may be used. This uses a less elongated epidermis for areas that do not require elongation, and a more elongated epidermis for areas that require more elongation. Alternatively, as in a general trim cover, two or more kinds of skins, or one skin with little elongation may be cut three-dimensionally from the beginning, or may be combined. Alternatively, skins of two or more colors may be used.

The fusing fabric 2 is in the form of a knitted fabric, a nonwoven fabric, a net, a paper, a tape, or a film.
It can be deformed or fused at 150℃, the fused part will not become hard even after fusion, and the material can be any material that satisfies the required temperature, for example,
There are nylon-based products with product names such as Nylon Half or Meltrow Wave.

If the cushion body 3 is a skinless mold, the skin will not peel off from the skin on the surface of the urethane mold after adhesion, unlike in the case of a skinned mold. Even if it is a skinned mold, it may be used as long as the required fusion part has a skinless part or the skin has been removed.

The slab 4 in FIG. 9 is partially placed on the cushion body 3, and has a lower specific gravity than the cushion body 3, giving it a soft feel. The molded slab or urethane mold 5 in Figure 10 is the slab 4 in Figure 9.
The purpose is to improve riding comfort. The cushion body 3 may be partially molded with different specific gravity. The drawings are explained using urethane molds, slabs, etc., but other cushion materials can also be used.

Furthermore, the present invention is widely applicable not only to vehicle seat bodies, but also to similar items such as interior door pads and other parts, and interiors such as furniture.

Effects of the Invention The manufacturing method of the present invention described above has the following effects.

a The above-mentioned drawbacks are eliminated compared to the conventional example using an adhesive.

(b) It is more accurate and easier than adhesive spraying because no fusing cloth is placed on areas that do not require gluing.

c When gluing the bag-shaped outer skin of the front bag to a urethane mold, it is difficult to spray adhesive uniformly at a predetermined position on the inside of the bag-shaped bag, but according to the present invention, it is possible to apply adhesive cloth in advance. This can be done accurately and easily by temporarily fixing it to a mold or skin.

d The thickness, melting point, etc. of the welding cloth can be selected depending on the material of the welding cloth, so the required welding strength or the welding that is suitable for the material and shape of the skin is better than the spray method. Are better.

[Brief explanation of drawings]

Figure 1 is a sectional view showing the process of attaching the skin to the outer periphery of the lower mold, Figure 2 is a sectional view showing the process of heating the skin, Figure 3 is a sectional view showing the process of compression molding the skin, and Figure 4 3A is a sectional view showing the process of placing the fusion fabric, FIG. 3A is a sectional view showing the process of heating and forming the fusion fabric together with the skin, and FIG. 5 is a sectional view showing the process of heating and deforming the fusion fabric. Figure 6 is a cross-sectional view showing the process of fusing using a pressing mold, Figure 7 is a cross-sectional view showing a heating compressor that preheats the cushion body, and Figures 8, 9, and 10 are cross-sections of each example of the seat body. It is a diagram. DESCRIPTION OF SYMBOLS 1...Skin, 2...Fusion fabric, 3...Cushion body, 4...Slab, 5...Forming slab or urethane mold, 6...Lower mold, 6A...Protrusion, 7...
Heater, 8, 8A...Upper mold, 9...Heater, 1
0,10A...Press mold, 11...Positioning pin,
12...Cushion body heating compressor, 13...Box,
14...Compression shaft, 16...Multi-hole pedestal, 17...Air exhaust hole, 17A...High temperature air intake hole.

Claims (1)

[Scope of Claims] 1. On the surface of a cushion body made of a skinless urethane mold or a cut-molded urethane slab, a skin is heat-molded with an upper mold and a lower mold having mold surfaces of the same shape as the surface. In the manufacturing method of the seat body, which is characterized in that the cushion body and the air in its internal bubbles are heated to a high temperature in advance, and then the cushion body and the air in its internal bubbles are heated to high temperature, , a manufacturing method for a seat body characterized by adhesive molding. 2. A highly elongated skin that is not heat-molded is adhered to the surface of a skinless urethane mold or cut-molded urethane slab cushion body by thermally melting a fusing cloth interposed between the skin and the above-mentioned cushion body. In the manufacturing method of the seat body to be molded,
A method for manufacturing a seat body, characterized in that the cushion body and the air in its internal bubbles are heated in advance to a high temperature, and then adhesive molding is carried out.