JPH0458358B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to a method of manufacturing a cushion body in which a pad is covered with a skin, such as a headrest or a seat body of an automobile seat.

<Prior art> Conventionally, for example, in manufacturing headrests for automobile seats, it has been common to cover a pad formed into a predetermined shape with a skin created in a separate process, and this method requires a large number of steps. The problem is that productivity is poor.

As a method of reducing the number of steps, a method of integrally molding the skin and the pad is known. This method involves molding the skin to match the shape of the pad in a vacuum mold, then injecting a foaming solution such as polyurethane resin into the skin and foaming it to integrally mold the skin and pad. be.

<Problems to be Solved by the Invention> However, in order to maintain comfort when sitting or in use, the skin is generally made of a breathable sheet, and the foaming solution is poured from inside the breathable skin. When foaming, the foaming solution leaks out from between the grains and textures of the epidermis and foams, and the area around the epidermis is covered with the exuded and foamed resin. For this reason, many defective cushion bodies are produced. or,
Since a bag-like shape like a headrest is made from a single piece of skin, it is necessary to use a special material with high extensibility for the skin, which limits the degree of freedom in material selection. Furthermore, when the pad is foam-molded, if the skin is stretched too much, the strength of the skin will decrease.
Design restrictions have also been added to the shape of the cushion body.

<Means for Solving the Problems> The present invention has been made in consideration of the above circumstances, and provides a method for manufacturing a cushion body in which the foaming solution does not leak out to the outside and the skin does not stretch too much. .

Therefore, in the present invention, a bag-like breathable skin with a narrow entrance into which a bag-like non-breathable film is inserted is inserted into a vacuum forming mold, the pressure inside the mold is reduced, the skin is vacuum-formed, and the foaming stock is It is characterized by being injected and molded into a pad.

Further, an adhesive is applied to either the non-breathable film or the skin, the film is inserted into the vacuum mold, the pressure inside the mold is reduced to vacuum form the skin, and a foaming stock solution is injected into the mold. The feature is that the pad is molded using the same method.

<Function> After inserting the breathable skin and the non-breathable film into a vacuum molding mold with the film inside, the pressure of the vacuum molding mold is reduced to bring the skin and film into close contact with the inner wall of the mold, and in this state, the inside of the film is inserted. A foaming solution is injected into the foam and foamed to form a pad.

The non-breathable film is located inside the epidermis to prevent the foaming solution from seeping out to the outside of the epidermis.

The breathable skin is pouch-shaped with a narrow entrance, so the breathable skin and non-breathable film do not separate when demolding.
Adhesives are not required unless necessary for molding.

<Example> Hereinafter, an example in which the present invention is applied to a head rest of an automobile seat will be specifically described in accordance with the attached drawings and process order.

FIG. 1 is a perspective view of a skin material 1 used in the present invention. This skin material 1 is made of an air-permeable material, has a tongue piece 1a formed in a part thereof, and other parts except for this tongue piece 1a are formed into a bag shape that matches the shape of the pad. This can be made into a bag shape by sewing the ends of each part with sewing thread, or by high frequency welding or the like. FIG. 2 shows an air-impermeable film 2 inserted into the bag-shaped skin 1, and this film 2 is also shaped like a bag with only the tongue piece 2a open. As the breathable film 2, for example, a resin film such as polyurethane or polyvinyl chloride is used. The skin 1 and film 2, both formed into a bag shape, are inserted into a vacuum mold 5 as shown in FIG. 3. The vacuum forming mold 5 has a cavity 5a consisting of a hollow part in the shape of a head rest.
It consists of a suction hole 5b opened in the cavity 5a, an injection port 5d for the foaming stock solution, and a pressure reduction path 5c connected to a pressure reduction means. The skin 1 and the film 2 are inserted into the cavity 5a of the vacuum mold 5. First, the skin 1 is inserted, and then the film 2 is inserted into the skin 1.
In this case, the tongue piece 1a of the skin 1 and the tongue piece 2a of the film 2 are pulled out from the vacuum mold 5 and fixed between the fixing frames 4 attached to both sides of the injection port 5d. In this way, the skin 1 inserted into the vacuum mold is formed into a bag shape to match the shape of the pad to be molded, thereby increasing the elongation of the skin by 10 to 20%.
can be suppressed to If it is necessary to adhere the skin 1 and the film 2, an adhesive may be applied to either or both of the inner surface of the skin 1 and the outer surface of the film 2 in advance. This adhesive can be either a pressure-sensitive adhesive or a heat-sensitive adhesive.

Next, as shown in FIG.
The air inside the vacuum forming mold 5 is suctioned from c, and this suction force brings the skin 1 and film 2 into close contact with the inner wall of the cavity 5a, and in this state, polyurethane, etc. Foaming stock solution 6
is injected into the cavity 5a. Then, as shown in FIG. 5, while maintaining the reduced pressure state, that is, while keeping the skin 1 and film 2 in close contact with the inner wall of the cavity 5a, the headrest stay 7 is inserted through the injection port 5d, and the cap 10 is closed. Inlet 5
After closing d, the foaming stock solution is foamed to form a pad. Since the inner surface of the skin 1 is covered with an air-impermeable film during this molding, the foaming stock solution will not leak out of the skin. In addition, when the adhesive is a heat-sensitive adhesive, the skin 1 and the film 2 can be bonded together at the same time as the pad molding by injecting the foaming solution and heating the inside of the vacuum mold. Often, after the cushion body (pad) is molded, it may be removed from the vacuum mold and bonded by hot pressing.

Finally, the tongues 1a, 1a of the skin 1 and the tongues 2a, 2a of the film 2 are joined together by appropriate means such as suturing.

FIGS. 6 and 7 are perspective views of another example of the headrest formed as described above. In the case of the cushion shape as shown in FIG. 6, it is not necessary to bond the skin 1 and the film 2. In the case of a cushion shape as shown in FIG. 7, it is necessary to bond the skin 1 and the film 2. FIG. 8A is a sectional view taken along the line -- in FIG. 7. In FIG. 8, 11 is a pad formed by foaming the foaming solution, and as shown in the enlarged view (b), the skin 1 and the film 2 are bonded to each other by the adhesive 12.
It is glued through.

<Effects of the Invention> As described above, according to the present invention, since the epidermis and pad are integrally molded, the process of covering the epidermis onto the pad is reduced, and since the breathable epidermis is bag-shaped, the breathable epidermis and the non-breathable epidermis can be separated. Even without adhering a sex film in advance,
The epidermis and film can be demolded without peeling, and since the non-breathable film is inserted into the inner surface of the epidermis, the foaming solution will not leak out of the epidermis, and since the epidermis is already bag-shaped, Since there is no need to stretch the epidermis and make it into a bag-like shape as in the past, it is possible to use ordinary skin materials that do not cause excessive stretching of the epidermis, which has the effect of expanding the room for material selection and the degree of freedom in design. .

[Brief explanation of the drawing]

Figures 1 and 2 are perspective views of an example of the skin and film used in the present invention, Figures 3 to 5 are sectional views in the order of manufacturing steps, and Figures 6 and 7 are another example of the headrest. FIG. 8A is a sectional view taken along the - line in FIG. 7, and B is an enlarged view of the main part of FIG. 1...Skin, 2...Film, 5...Vacuum mold, 1
1...Putsudo.

Claims (1)

[Claims] 1. A bag-like breathable skin with a bag-like non-breathable film inserted inside is inserted into a vacuum mold, the pressure inside the mold is reduced to vacuum form the skin, and the foaming stock solution is poured into the mold. A method of manufacturing a cushion body, characterized by injecting the material into the cushion body and molding the cushion body. 2. The method of manufacturing a cushion body according to claim 1, wherein an adhesive is applied to either the non-breathable film or the skin.