JPH05185439A - Foam molding method and foaming mold of pad materials different in hardness - Google Patents

Abstract

PURPOSE:To prevent the mutual mixing of different foamable solutions by respectively injecting foamable solutions different in hardness in a plurality of small chambers of a foaming mold and preventing the foamable solution high in flow velocity from overflowing the partition wall of a lower mold to flow in the small chamber on the side of the foamable solution low in flow velocity in order to certainly obtain desired pad materials different in hardness. CONSTITUTION:The lower mold 22 of a foaming mold 21 is partitioned by partition walls 25 to form a plurality of small chambers 27a-27g. Barrier walls 31, 32 are provided to the small chambers 27a, 27b in which the foamable solution high in flow velocity or much in injection quantity among foamable solutions different in hardness is injected to adjust flow velocity. Further, slits are formed to the partition wall 25 to adjust flow velocity. Each of the barrier walls is formed from a pin and the pad piece engaged with said pin.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foam molding method and foam molding die for different hardness pad materials.
A partition wall having a low height is provided in the lower mold of the foaming mold to form a plurality of small chambers, and a foaming liquid composed of a compounding system having a different hardness is injected into each of the plurality of small chambers, and a pad material having a partially different hardness. TECHNICAL FIELD The present invention relates to a foam molding method and a foam molding die for a pad of different hardness, which are integrally molded.

[0002]

2. Description of the Related Art Conventionally, a pad material for a seat of a vehicle or the like has been required to have various hardness according to the purpose of use. In addition, pad materials with partially different hardness are integrally foam-molded,
The hardness is changed according to the seating part. When molding this different hardness pad material, a foaming liquid composed of a certain standard hardness, for example, a polyol-based foaming liquid is mixed with an isocyanate, a tin-based catalyst, a flame retardant, etc., and a foaming aid is added to this. Then, a pad material having a hardness lower than the standard hardness,
A foaming liquid such as a pad material having high hardness is obtained.

These foaming liquids having different hardness are poured into each small chamber formed in the lower mold of the foaming mold. As shown in FIG. 6, when molding a seat back of a vehicle, for example, a plurality of partition walls 5 having a relatively low height are formed in the lower mold 3 of the foam molding die 1, and a plurality of partition walls 5 are used. To form the small chamber 7. The foaming liquids of different hardness formed by the above method are injected into the plurality of small chambers 7, respectively, and the central portion with which the back of the occupant abuts is molded into a soft pad material having a good feel, and both side portions are hard with a good support feeling. The different hardness pad material formed in the above is integrally foam-molded. In FIG. 6, reference numeral 8 is a convex portion for forming an armrest accommodating concave portion, and reference numeral 9 is a convex portion for forming a headrest accommodating concave portion.

[0004]

When foaming a conventional pad material of different hardness, since foaming liquids of different hardness are injected, the injection amount of foaming liquid, the type of foaming liquid, the shape of the lower mold. And the inclined state, the injection conditions are different, and the injection conditions are also different with respect to the size, shape, position, etc. of the different hardness part. Therefore, the flow velocity of the injected foaming liquid is different for each small chamber 7, especially There was a possibility that the foaming liquid having a high flow velocity would flow into the small chamber having a low flow velocity on the downstream side of the mold 3 and the different foaming liquids would be mixed with each other, whereby a pad material having a desired different hardness could not be obtained. ..

The object of the present invention is to, when pouring a foaming liquid having different hardness into a plurality of small chambers, change the pouring conditions depending on the pouring amount of the foaming liquid, the type of the foaming liquid, the shape of the lower mold and the inclined state. The flow rate of the injected foaming liquid can be adjusted in each small chamber, especially in the case of the lower mold. It is possible to prevent the foaming liquid having a high flow velocity from flowing into the small chamber having a low flow velocity on the downstream side and mixing the different foaming liquids with each other, and it is possible to reliably obtain a pad material having a desired different hardness. The invention provides a foam molding method and foam molding die for a pad of different hardness.

[0006]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and the method for foam-molding a different hardness pad material according to claim 1 is that a partition wall having a low height is provided on the lower mold. In the foam molding method of a pad material of different hardness, which comprises forming a plurality of small chambers, injecting a foaming liquid composed of a compounding system of different hardness into each of the plurality of small chambers, and integrally molding a pad material having a partially different hardness, Among the foaming liquids with different hardnesses that are injected into multiple small chambers, the flow speed of the foaming liquid with a high flow velocity or the liquid with a large injection volume is injected into the small chambers. It is characterized in that it is adjusted by being provided.

Further, in the foam mold of the different hardness pad material according to claim 2, a partition wall having a low height is provided in the lower mold of the foam mold to form a plurality of small chambers, and the plurality of small chambers are different from each other. In a foam molding die of different hardness pad material in which a foaming liquid having a hardness compounding system is injected to integrally mold pad materials having different hardnesses, the compounding system having different hardness is injected into the plurality of small chambers. Of the foaming liquid, a barrier is provided in a small chamber into which the foaming liquid having a high flow velocity or a large amount of foaming liquid is injected, in the direction substantially orthogonal to the partition wall, so that the flow velocity of the foaming liquid can be adjusted. It is characterized by

Further, the foam molding die of the different hardness pad material according to claim 3 is characterized in that the barrier is formed in one or more steps in the small chamber and is integrally formed with the lower die.

According to a fourth aspect of the foam molding die of the different hardness pad material, the barrier is a pin protruding from the small chamber,
It is characterized by being formed from a pad piece locked to the pin.

[0010]

According to the foam molding method for a pad material of different hardness according to claim 1 of the present invention, among the foaming liquids having different hardnesses and injected into a plurality of small chambers, the foaming liquid having a high flow rate, Alternatively, since the flow rate of the foaming liquid in the small chamber into which the large amount of foaming liquid is injected is adjusted by providing a barrier in the lower mold, the barrier height, the number, the position, etc. can be set as appropriate. Due to the time difference overcoming, the foaming liquid having a high flow velocity can be adjusted to be slower like the foaming liquid having a slow flow velocity, and the foaming liquids having different hardness are mixed on the downstream side of the lower mold. Can be prevented.

According to the foam molding die of the different hardness pad material of the second aspect, among the foaming liquids having different hardnesses which are injected into the plurality of small chambers, the foaming liquid having a high flow velocity, or Since the small chamber into which a large amount of the foaming liquid is injected is provided with a barrier in a direction substantially orthogonal to the partition wall, a liquid pool is formed inside this barrier, and due to the difference in time over which the barrier is crossed, the foaming liquid with a high flow velocity is generated. The flow velocity can be adjusted to be slow like the foaming liquid having a low flow velocity, and it is possible to prevent the foaming liquids having different hardnesses from being mixed in the downstream side of the lower mold.

According to the foam molding die of the different hardness pad material of the third aspect, since the barrier is formed in the small chamber in one or more steps, and is formed integrally with the lower die, The structure can be simplified, the height of the barrier,
By appropriately setting the number, position, etc., the flow rate of the foaming liquid can be adjusted in various ways.

Further, in the foam molding die of the different hardness pad material according to the fourth aspect, the barrier is formed by the pin protruding from the small chamber and the pad piece locked by the pin, so that the barrier is formed. By appropriately setting the height, number, position, etc. of the foam, the flow speed of the foaming liquid can be adjusted in various ways, and the pad piece and the foaming liquid are integrally joined, and in this state, the different hardness pad material is formed. Therefore, the recesses due to the presence of the barrier are not formed in the different hardness pad material, and the degree of freedom in designing the shape is increased.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The foaming method and foaming mold for a different hardness pad material according to the present invention will be described below in detail with reference to the drawings. 1 and 2 respectively show an outline of a first embodiment of a foam molding die for carrying out the foam molding method for a different hardness pad material of the present invention. In this embodiment, a seat back of a vehicle seat is shown. The case where the present invention is applied to the different hardness pad material used for is described, but the present invention is not limited to this. In addition, the first and second foaming liquids 11 and 1 having different hardnesses are mixed.
Although the case where 2 is used will be described, a third foaming liquid can also be used.

The first foaming liquid 11 has a large foaming amount,
It consists of a foaming liquid with a high flow rate. Further, the second foaming liquid 12 is composed of a foaming liquid having a small foaming amount and a slow flow velocity. Further, the first foaming liquid 11 is a foaming liquid with a large injection amount,
The second foaming liquid 12 can be read as a foaming liquid with a small injection amount. The first and second foaming liquids 1
1 and 12 are, for example, formed by mixing a polyol-based foaming liquid with an isocyanate, a tin-based catalyst, a flame retardant, and the like, and adding a foaming auxiliary thereto, and having a hardness lower than a certain standard hardness. Alternatively, a foaming liquid such as a pad material having a high hardness can be obtained.

The foaming mold 21 comprises a lower mold 22 and the lower mold 2.
It is formed from an upper mold 23 that is matched with the mold 2. The lower die 22 has a thickness lower than the lower die 22 and a thickness of 5-10.
A plurality of mm partition walls 25 are formed, and the plurality of partition walls 25 are formed.
A plurality of small chambers 27a to 27g are formed between them. still,
The numbers of the partition wall 25 and the plurality of small chambers 27a to 27g are not limited to those shown in the figure. Further, reference numeral 29 in FIG. 1 denotes a convex portion for forming a concave portion for accommodating the armrest, and reference numeral 30.
Is a convex portion for forming a concave portion for accommodating the headrest.

The small chambers 27a and 27b correspond to the portions of the seat back which come into contact with the back of the seated person. The small chambers 27a and 27b have a large amount of foaming and a first foaming liquid which is a foaming liquid having a high flow velocity. Liquid 11 is injected. The small room 2
Two upper and lower barriers 31, 32 are formed in 7a, 27b in a direction substantially orthogonal to the partition wall 25. Although the barriers 31 and 32 are formed in two upper and lower stages in this embodiment, they may be one stage or three or more stages.

The flow velocity can be adjusted by appropriately adjusting the height of the barriers 31, 32. Further, as shown in FIG. 3, by forming slits 35 in the barriers 31 and 32, the flow velocity of the first foaming liquid 11 can be adjusted. Furthermore, as shown in FIG. 4, the upper stage may be formed by the barrier 31 without the slit 35, and the lower stage may be formed by the barrier 32 having the slit 35. The barriers 31 and 32 may be formed higher or lower than the partition wall 25. Also barriers 31,3
When 2 is formed high, a slit is formed in the foamed different hardness pad material, but this recess can be used as a pulling portion of the skin material.

Next, the foam molding method of the different hardness pad material will be described. Small chamber 27c of the lower mold 22 of the foaming mold 21
The second foaming liquid 12 having a slow flow rate is sequentially injected into 27 g from the injection nozzle 37. Next, the small chamber 27 of the lower mold 22
Nozzle 3 for injecting first foaming liquid 11 having different hardness into a and 27b
Sequentially inject from 7. Incidentally, the first and second foaming liquids 1
1 and 12 are sequentially injected into the respective small chambers through the injection holes 23a formed in the upper mold 23, but they may be injected in a state where the upper mold 23 is opened and then the upper mold 23 is closed. ..

The first foaming liquid 11 having a high flow velocity is the barrier 3
The flow velocities are adjusted to be slow by 1, 32 so that the first and second bubbling liquids 11 and 12 arrive at the downstream side of the lower mold 22 substantially at the same time. Foam mold 21
The second foaming liquid 12 having a slow flow velocity injected into the small chambers 27c to 27g of the lower mold 22 is sequentially foam-cured in each of the small chambers 27c to 27g, and the first foaming liquid having a high flow velocity injected into the small chambers 27a and 27b. The foaming liquid 11 is also sequentially foam-cured in the small chambers 27a and 27b, and the first foaming liquid 11 is foam-molded into a relatively soft pad material and the second foaming liquid 12 is foam-molded into a hard pad material. As the process progresses, they are integrated to form a different hardness pad material.

FIG. 5 shows a second example of the foam molding die 21 of the present invention.
The outline of the embodiment is shown, and the portions corresponding to those of the first embodiment described above are denoted by the same reference numerals and the detailed description thereof will be omitted. However, instead of the barriers 31 and 32, barriers are provided. A pin 41 protruding from the lower mold 22, and the pin 41
And a pad piece 42 that is locked while being pierced from above. The pad piece 42 is made of chip urethane or the like, and it is not necessary to make it thin like the barriers 31 and 32, and can be made into a quadrangle.

The pin 41 and the pad piece 4 as the barrier
The flow velocity of the first foaming liquid 11 can be variously adjusted by appropriately setting the height, the number, the position, the shape, etc. of the two. Further, the pad piece 42 and the first foaming liquid 11 are integrally joined, and in this state, the different hardness pad material is molded. By taking out the different hardness pad material from the lower mold 22 of the foam molding die 21, the pad piece 42 is formed. Can be extracted from the pin 41, and the pad piece 42 can be integrally embedded in the different hardness pad material. Therefore, the recesses due to the presence of the barrier are not formed in the different hardness pad material, and the degree of freedom in designing the shape is increased.

[0023]

EFFECTS OF THE INVENTION The above is the method and configuration of the foam molding method and foam molding die of the different hardness pad material according to the present invention. According to such a method, a plurality of small chambers are injected. Among the foaming liquids composed of compounding systems of different hardness, the flow speed of the foaming liquid with a high flow speed or the foaming liquid in the small chamber into which a large amount of foaming liquid is injected was adjusted by providing a barrier in the lower mold, By appropriately setting the height, number, position, etc. of the barriers, the foaming liquid having a high flow velocity can be adjusted to have a low flow velocity similarly to the foaming liquid having a slow flow velocity due to the time difference over the barrier. It is possible to prevent the foaming liquid composed of a compounding system having different hardness from being mixed on the downstream side of the lower mold, and to reliably obtain a pad material having a desired different hardness.

Further, according to the foaming mold of the different hardness pad material according to the present invention, among the foaming liquids having different hardnesses which are injected into the plurality of small chambers, the foaming liquid having a high flow velocity,
Alternatively, since a barrier is provided in a small chamber into which a large amount of foaming liquid is injected, in a direction substantially orthogonal to the partition wall, a liquid pool is formed inside this barrier, and due to the time difference over the barrier,
It is possible to adjust the flow speed of a foaming liquid with a high flow speed to be slow like the foaming liquid with a low flow speed, and to prevent the mixing of foaming liquids of different hardness in the downstream side of the lower mold. You can

[Brief description of drawings]

FIG. 1 is a perspective view of a lower mold of a foam molding die according to a first embodiment of the present invention.

FIG. 2 is a cross-sectional view of the foam molding die according to the first embodiment of the present invention.

FIG. 3 is a perspective view of a modified example of the lower mold of the foaming mold of the present invention.

FIG. 4 is a partial perspective view of a modified example of the lower mold of the foaming mold of the present invention.

FIG. 5 is a sectional view of a foam molding die according to a second embodiment of the present invention.

FIG. 6 is a perspective view of a lower mold of a conventional foaming mold.

[Explanation of symbols]

 11 1st foaming liquid 12 2nd foaming liquid 21 Foaming mold 22 Lower mold 23 Upper mold 25 Partition wall 27a-27g Small chamber 31 Partition wall 32 Partition wall 35 Slit 37 Injection nozzle 41 Pin 42 Pad piece

Continuation of front page (51) Int.Cl. ⁵ Identification number Office reference number FI technical display area // B29K 105: 04 B29L 31:58 4F

Claims (4)

[Claims] 1. A lower wall of a foaming mold is provided with a partition wall having a low height to form a plurality of small chambers, and a plurality of small chambers are respectively filled with a foaming liquid of a compounding system having a different hardness to partially fill the small chambers. In a foam molding method for a pad material of different hardness, which integrally molds pad materials having different hardnesses, among the foaming liquids having different hardnesses and injected into the plurality of small chambers, a foaming liquid having a high flow velocity or an injection amount. A method for foam-molding a different hardness pad material, characterized in that the flow velocity of the foaming liquid in a small chamber into which a large amount of foaming liquid is injected is adjusted by providing a lower mold with a barrier. 2. A lower wall of a foaming mold is provided with a partition wall having a low height to form a plurality of small chambers, and a plurality of small chambers are respectively filled with a foaming liquid having a compounding system having a different hardness to partially fill the small chambers. In a foam molding die for pad materials of different hardness, which integrally form pad materials having different hardnesses, among the foaming liquids having different hardnesses and injected into the plurality of small chambers, the foaming liquid having a high flow velocity or the injection amount A foam molding die for different hardness pad material, characterized in that a barrier is provided in a small chamber into which a large amount of foaming liquid is injected in a direction substantially orthogonal to the partition wall so that the flow velocity of the foaming liquid can be adjusted. .. 3. The foam molding die for a different hardness pad material according to claim 2, wherein the barrier is formed in one or more stages in the small chamber and is integrally formed with a lower die. 4. The foam molding die for a pad material of different hardness according to claim 2, wherein the barrier is formed of a pin projecting from the small chamber and a pad piece locked to the pin. ..