JPH0462844B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Object of the Invention] (Industrial Application Field) The present invention relates to a method for manufacturing a cushioning plate-like product whose surface is coated with a cushioning material.

(Prior art) For example, as shown in FIG. 5, a sun visor installed in an automobile front window has a main body a in the form of a horizontally long plate, and a support shaft b protruding from both sides of the upper edge. It is swingably supported by the upper edge of the window with the required braking force by the shaft b. Under normal conditions, it is swung upward for storage, and when in use, it is hung downward to guide it to a desired light-shielding position.
To select these positions, the main body a must be operated by directly placing the hand on the main body a, and the main body a must have a certain degree of rigidity so as not to vibrate due to the vibrations of the automobile. On the other hand, for safety reasons, flexibility is required to reduce interference with the human body.

In view of the above requirements, the sun visor body a generally has a structure in which a highly rigid core plate c is covered with a urethane foam sheet d provided with an outer skin e over both surfaces and the entire periphery. As shown in FIG. 6, a sun visor with such a structure has a core plate c that is
A urethane foam sheet d with an outer skin e attached to the surface thereof is wrapped and attached to both sides of a core plate c. Some have urethane foam sheets pasted on one side at a time.

In this way, cushioning plate-like products with a core plate inside and the entire surface including the periphery covered with a urethane foam sheet require the work of pasting each urethane foam sheet onto the core plate, which requires a preliminary process. However, this method involves attaching double-sided tape or applying adhesive to the urethane foam sheet, which often relies on manual labor, resulting in low productivity and high costs.

(Problems to be Solved by the Invention) As described above, in manufacturing cushioning plate-like products such as automobile sun visors, the process of attaching double-sided urethane foam sheets to the core plate requires a large number of man-hours, resulting in low productivity. In view of the problem of increased costs, the method for manufacturing a cushioning plate-like product of the present invention is as follows:
The purpose is to omit the manual process of assembling the urethane foam sheet to the core plate, and to provide a method for manufacturing products with high productivity and at low cost.

(Structure of the Invention) (Means for Solving the Problems) In order to achieve the above object, in the method for manufacturing a cushioning plate-like product of the present invention, two urethane foam sheets surface-treated with an outer skin are stacked on the back side. By joining the periphery of the urethane foam sheet, it is formed into a bag shape that matches the outer shape of the product, and this bag-shaped urethane foam sheet is inserted into a mold for molding the product.
A method is used in which the inside of the bag is filled with synthetic resin by injection molding.

(Function) With this method, the core plate is formed between two urethane foam sheets, and a cushioning plate-like product whose entire outer surface is covered with the urethane foam sheet is formed all at once. The injection pressure causes the resin to enter the minute recesses on the back side of the urethane foam, so the core plate synthetic resin layer and the urethane foam layer are strongly bonded. No double-sided tape or adhesive required. In addition, since the outer contour of the entire body is adjusted by the mold, the appearance is made beautiful. The process of attaching the urethane foam sheet is absorbed into the injection molding process, shortening the process and producing a low-cost product.

(Example) Hereinafter, a method for manufacturing an automobile sun visor will be described in detail with reference to the drawings.

First, a urethane foam sheet 1 is surface-treated with a skin 2 made of leather, plastic, paper, cloth, flocked hair, wood, etc., and as shown in Figure 1, this is folded into two sheets. Layer them together and trim to match the outer shape of the sun visor body.
The peripheral edge 3 is sutured to form a bag.

Urethane foam sheet 1 formed in this way
As shown in FIG. 3, it is inserted into synthetic resin injection molding molds 4 and 5, and the synthetic resin is injected into the inner cavity 6 between the two stacked urethane foam sheets (arrow P).

The injected synthetic resin is filled into the inner cavity 6 by pushing and expanding the urethane foam sheet 1.
It is thermosetted and formed into a core plate 7, as shown in FIG. In this case, the outer skin 2 of the urethane foam sheet 1 is brought into contact with the inner surfaces of the molds 4 and 5 by injection pressure, and the core plate 7 is cured in that state, so that the outer shape is adjusted and the product is manufactured. Moreover, since the synthetic resin layer penetrates into the minute recesses on the back surface of the urethane foam sheet 1 and hardens, the synthetic resin layer and the urethane foam sheet layer are firmly bonded.

Fig. 2 shows another embodiment, in which two urethane foam sheets 1 whose surface has been treated with an outer skin 2 are stacked on top of each other with their backs facing each other, and the peripheral edge 3 is sewn to match the outer shape of the sun visor body. It is shaped like a bag, which is inserted into a mold, and synthetic resin is injected into the inner cavity of the bag to form the core material and at the same time form the sun visor.

In addition, in order to join the peripheral edges of the urethane foam sheet 1, adhesive or welding means other than stitching may be used. Further, the sun visor is provided with a support shaft b, as illustrated in FIG. 5, and in the case of the method of this invention, it is injection molded integrally with the core plate 7 using molds 4 and 5. As shown in FIGS. 1 and 2, the urethane foam sheet 1 is located at the portion where the support shaft 8 protrudes.
The end edge 3a is left open without being sutured, and the support shaft 8 is injection molded through this open part.

〔Effect of the invention〕

As described above, the method for manufacturing a cushioning plate-like product according to the present invention includes forming a urethane foam sheet into a bag shape to match the outer shape of the product, and inserting the bag-like urethane foam sheet into a mold. By injection molding a synthetic resin inside a bag-shaped interior, a product with a urethane foam sheet covering the entire surface of a synthetic resin core board is manufactured.The process of attaching the urethane foam sheet is included in the injection molding process. The process can be shortened by absorption, and the synthetic resin layer and urethane foam sheet layer can be firmly bonded without using adhesives or double-sided tape, which has the effect of providing products with high productivity and low cost.

[Brief explanation of the drawing]

Fig. 1 is a perspective view of a bag-shaped urethane foam sheet in the process of manufacturing a sun visor according to an embodiment of the present invention, Fig. 2 is a perspective view of a bag-shaped urethane foam sheet of a sun visor according to another embodiment, and Fig. 3 is an injection molded urethane foam sheet. FIG. 4 is a cross-sectional view of a sun visor manufactured according to the present invention; FIG. 5 is a perspective view illustrating the general structure of a sun visor; and FIG. 6 is a conventional method for manufacturing a sun visor. FIG. 1... Urethane foam sheet, 2... Outer skin,
3... Periphery, 4, 5... Mold, 6... Inner cavity, 7...
... Core plate, 8... Support shaft.

Claims (1)

[Claims] 1 Two urethane foam sheets that have been surface-treated with an outer skin are stacked back to back and their peripheral edges are joined to form a bag shape that matches the outer shape of the product. A method for producing a cushioning plate-like product, which comprises inserting it into a mold and filling the bag-like interior with synthetic resin by injection molding.