JPH04371812A - Manufacture of cushion which is one with skin and has different hardness - Google Patents

Abstract

PURPOSE:To mold the skin integrally, in a manufacture of a cushion having different hardness. CONSTITUTION:A molding tool 10 is constituted of a bottom force 11 and top force 12, made dividable into two and the skin 14 is made settable within the bottom force 11. Two slits 16, 18 are bored almost in parallel with each other in the top force 12 and raw material separation sheets 20, 22 are supported respectively as partition materials. The cavity of a molding tool 10 is divided into a seating part (general part) 30 partitioned by the bottom force 11, top force 12, raw material separation sheets 20, 22 and side parts (part having different hardness) 32, 34 partitioned by the bottom force 11, the top force 12 and the raw material separation sheet 20 or the raw material separation sheet 22.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a cushion with different hardness, which has an integrated skin structure and partially has different hardness.

0002

[Prior Art] Conventionally, the manufacturing of seat cushions for automobiles has been carried out simply and generally by injecting a foaming material into the cavity of a mold consisting of a lower mold and an upper mold. It is.

On the other hand, as shown in FIG.
The side part 74 of the seat part 72 has a bulging shape, and the side part 74 has a bulging shape.
It is said that it is preferable to make the cushion harder than the cushion, so-called a cushion with different hardness, in order to make it difficult for the occupant to fall down when driving on a rough road, and to make it easier to perform a good driving operation.

[0004] Incidentally, cushions with different hardness that partially differ in hardness have been conventionally manufactured by the following method. That is, as shown in FIG. 4, the cavity surface 76A of the lower mold 76
In this method, a mold in which convex partition walls 76B and 76C that partition the cavities are erected with gaps 80 and 82 left between them and the cavity surface 78A of the upper mold 78 is used, and these partition walls 76B and 76
This is done by injecting different types of foaming agents into the respective cavities separated by C and foaming them. As a result, the seating part 72 (general part) and the side part 74 (different hardness part)
The blowing agents are kept from mixing with each other. In some cases, the partition walls separating the cavities also serve as grooves for fixing the outer skin of the cushion to the urethane. In addition, as related prior art, Japanese Patent Application Laid-Open No. 63
-218316, etc.

[0005]

However, in the manufacturing method described above, convex partition walls 76B and 76C are provided on the cavity surface 76A of the lower die 76 to partition the cavity. Therefore, when manufacturing a so-called skin-integrated cushion in which the foam and the skin are integrally molded by foaming, which is used to manufacture a cushion with a concave design, when setting the skin on the cavity surface 76A of the lower mold 76, The epidermis is separated from the walls 76B, 76
It is necessary to follow C. Therefore, it becomes extremely difficult to set the skin on the cavity surface 76A of the lower mold 76, and the skin cannot be completely aligned with the partition walls 76B and 76C, resulting in a deterioration in the quality of the product's appearance. For this reason, in manufacturing cushions of different hardness, it has been virtually impossible to integrally mold the cushion body and the skin.

[0006] In consideration of the above facts, an object of the present invention is to provide a method for manufacturing a cushion with an integrated skin of different hardness, in which the cushion body and the outer skin can be integrally molded.

[0007]

[Means for Solving the Problems] The present invention as set forth in claim 1 includes the step of laying a skin on the inside of one mold of a mold that can be divided into two, and placing a partition material supported by the other mold on the skin. a step of partitioning the inside of the mold by arranging them so as to abut or be close to each other, and applying a foaming agent to each of the partitioned areas so that adjacent areas of the partitioned areas each become a foam having a different hardness. It is characterized by including a step of injecting and foaming.

[0008]

[Function] In the present invention as set forth in claim 1, the partitioning material is not supported on the mold on the side where the skin is laid of the mold which can be divided into two, and the partitioning material is supported only on the other mold. Therefore,
When setting the skin inside the mold, the partition material does not get in the way, so the skin can be easily and completely set along the inside of the mold, and then each area separated by the partition material It is possible to foam the foam by injecting different types of foaming agents into the foam to produce foams with different hardness. Therefore, in manufacturing a cushion of different hardness, the cushion body and the skin can be integrally molded.

[0009]

[Embodiment] An embodiment of the present invention will be described with reference to FIG.

As shown in FIG. 1, the mold 1 of this embodiment
0 is composed of a lower mold 11 and an upper mold 12, which can be divided into two parts, which can be closed and connected using a clamp or the like. The lower mold 11 of the mold 10 has a concave design, and together with the upper mold 12 forms a cushion shape. Also,
A skin 14 for integral skin foaming is set on the side surface of the cavity of the lower mold 11, and serves as the skin of the finished sheet product.

The upper mold 12 has two slits 16 and 18.
are bored approximately parallel to each other, and these slits 16, 1
8, raw material separation plates 20 and 22 as partitioning materials, respectively.
is supported. These raw material separation plates 20 and 22 are
Each has a T-shaped cross section, and has leg portions 20A and 22A.
can be inserted into the slits 16 and 18, respectively. Further, the tips of the legs 20A and 22A of the raw material separating plates 20 and 22 are in contact with the skin 14, respectively, and the mold 1
Cavity 0 has a lower mold 11, an upper mold 12, and a raw material separation plate 20.
and a seating area as an area partitioned by the raw material separation plate 22 (
General part) 30, lower mold 11, upper mold 12 and raw material separation plate 2
0 or the side part as an area partitioned by the raw material separation plate 22 (
It is completely divided into different hardness parts 32 and 34.

[0012] An injection port 24 is bored in a portion communicating with the seating portion 30 of the cavity of the upper mold 12, and a relatively soft foam is formed from this injection port 24 into the seating portion 30 of the cavity of the mold 10. It is designed to inject a foaming agent. In addition, injection ports 26 and 28 are formed in portions communicating with the side portions 32 and 34 of the cavity of the upper mold 12, respectively, and from these injection ports 26 and 28, the side portions 32 and 34 of the cavity of the mold 10, A foaming agent is injected into 34 to form a relatively hard foam. These inlets 24,
26 and 28 are each provided with an opening/closing door (not shown).

Next, a method of manufacturing the skin-integrated cushion of different hardness according to this embodiment will be explained. First, the skin 14 is set on the side surface of the cavity of the lower mold 11, and the upper mold 12 is closed and connected using a clamp or the like. Next, the raw material separation plate 20,
22 into the slits 16 and 18, and the legs 16A and 1
Each tip of 8A is brought into contact with the epidermis 14. As a result, the seating part 30 and the side part 3 of the cavity of the mold 10 into which different types of foaming agents (resulting in foams with different hardness) are injected.
2 and 34 can be completely separated.

Next, the injection ports 24, 26, 28 of the upper mold 12
The opening/closing door is opened, different types of foaming agents are injected using injection machines (not shown), and the opening/closing door is closed.

When each foaming agent is foamed in this state, each foaming agent is They do not mix with each other and foam independently to form foams with different hardnesses. When foaming progresses and the viscosity of each foam increases, the raw material separation plates 20 and 22 are raised and extracted from the slits 16 and 18. As a result, different types of foaming agents come into contact and are integrated. Therefore, in the finished seat cushion, the side portions 32 and 34 improve the holding performance of the seat, and the riding comfort of the seating portion 30 can be ensured at the same time.

Furthermore, until the end of foaming, the raw material separating plates 20, 2
2, it is possible to separate the foam that makes up the seating part 30 and the foam that makes up the side parts 32 and 34 of the finished product, and by reducing the interlocking between each foam, the cushion can further improve performance.

As described above, in this embodiment, the lower mold 11
When setting the skin 14 inside the raw material separation plate 20,
22 does not get in the way, the skin 14 can be easily and completely set along the inside of the lower mold 11, and then the seating part 30 and the side parts 32, 34 separated by the raw material separating plates 20, 22 are separated. It is possible to inject foaming agents of different types to produce foams with different hardness. Therefore, in manufacturing a cushion of different hardness, the cushion body and the skin can be integrally molded.

In the above embodiment, the raw material separating plate 20,
The tips of the legs 20A and 22A of 22 are connected to the epidermis 1, respectively.
4, but instead of this, a plurality of rectangular notches (about 1 mm in depth) may be provided at the tips of the legs 20A, 22A of the raw material separating plates 20, 22. Further, as shown in FIG. 2, the handles 20B, 22B of the raw material separating plates 20, 22 abut against the edges 16A, 18A of the slits 16, 18, respectively, and the leg parts 20A, 22A of the raw material separating plates 20, 22 A gap 38 may be formed between the distal end portion and the epidermis 14. As a result, at the boundary between the foam constituting the seating portion 30 and the foam constituting the side portions 32 and 34, both foams coexist through the notch or gap 38, reducing the rigidity level difference at the boundary. It can be alleviated.

Further, in the above embodiment, the raw material separating plate 20,
22 can be inserted into and removed from the slits 16 and 18 of the upper mold 12, but instead of this, the raw material separation plates 20 and 22 can be inserted into and removed from the slits 16 and 18 of the upper mold 12.
It is also possible to have a fixed configuration.

[0020]

Effects of the Invention The method of manufacturing a cushion with different hardness with integrated skin includes the steps of laying a skin inside one mold of a mold that can be divided into two, and applying a partition material supported by the other mold to the skin. A step of dividing the inside of the mold by arranging them in contact with or in close proximity to each other, and injecting a foaming agent into each of the divided regions so that the adjacent regions of the divided regions each become a foam having a different hardness. Since the method includes the steps of foaming and foaming, it has an excellent effect in that the skin can be integrally molded in the production of cushions of different hardness.

[Brief explanation of drawings]

FIG. 1 is a cutaway perspective view showing a mold used for manufacturing a cushion with different hardness with integrated skin according to an embodiment of the present invention.

FIG. 2 is a cutaway perspective view of a mold used for manufacturing a cushion with different hardness integrated with the skin according to another embodiment of the present invention.

FIG. 3 is a perspective view showing a conventional cushion with different hardness.

FIG. 4 is a sectional view showing a conventional mold for a cushion of different hardness.

[Explanation of symbols]

10 Molding mold 11 Lower mold 12 Upper mold 14 Epidermis 20 Raw material separation plate (partition material) 22 Raw material separation plate (partition material) 30 Seating area (area) 32 Side part (area) 34 Side part (area)

Claims (1)

[Claims] Claim 1: A step of laying a skin on the inside of one mold of a mold that can be divided into two, and arranging a partition material supported by the other mold so as to contact or be close to the skin, and forming the inside of the mold. and a step of injecting a foaming agent into each of the divided regions to foam the divided regions so that adjacent regions of the divided regions each become a foam having a different hardness. A method for manufacturing a cushion with different hardness integrated into the skin.