JPH054237A - Manufacture of formed molded product having skin - Google Patents

Abstract

PURPOSE:To obviate the necessity for forming an insert and a skin into special shapes in the preparation of a formed molded product having the skin and to simply prevent the falling of a skin terminal even at the time of the manufacture of said product using no insert. CONSTITUTION:A skin 26 having a predetermined shape is applied to the cavity of a mold and a liquid foamable raw material 38 is injected in the skin to be integrally foamed along with the skin to prepare a foamed molded product having the skin. In this method, a magnet 36 is preliminarily embedded in the approach part of the skin terminal 26a of a cavity surface 34 and a magnetic force responding bodies 28 such as iron pieces are received in the skin 2 at the time of the application of the skin 26 to be attracted from the inside of the skin 26 by the magnet 36 and the liquid foamable raw material 38 is foamed while the skin terminal 26 is pressed and held to the cavity surface 34 by the magnetic force responding bodies 28.

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 foam-molded article with a skin, and more particularly to a method for foam-molding integrally with a skin.

[0002]

2. Description of the Related Art Automotive armrests, headrests,
For the pads and the like, a foam-molded article with a skin whose surface is covered with a skin is often used. Conventionally, as a method for easily manufacturing the foam-molded article with the skin, as shown in FIG. 6, the skin 10 molded into a predetermined shape is installed in the cavity 14 of the mold 12, and the urethane foam raw material or the like is placed in the skin 14. There is a method of injecting the liquid foaming raw material 16 and foaming the liquid foaming material 16 integrally with the skin to form a molded product (commonly called skin-integrated foam molding method).

However, in the above manufacturing method, a large opening or notch 18 is required in the skin in order to inject the liquid foaming raw material into the skin or to insert an insert for reinforcement or the like. .. Therefore, the skin installed in the cavity often falls into the skin due to the peripheral edge of the opening or notch 18, that is, the skin terminal 20 being softened by its own weight or by the heat retained by the molding die, and thus the skin terminal and the cavity. A gap is easily formed between the surfaces. As a result, the liquid foaming raw material leaks out of the epidermis from the gap between the skin terminal and the cavity surface to contaminate the outer surface of the epidermis, or due to the leakage, the foaming raw material in the epidermis runs short and causes deficiency, or There was a problem such as taking time to remove the burrs.

Conventionally, as a method for eliminating the above-mentioned problems, an insert which is installed in the skin during foam molding is used, and a skin end is sandwiched and held between a part of the insert and the cavity surface (Japanese Patent Publication No. 47-8154). Or a method of pressing the epidermal end against the cavity surface by interfering the protuberance with the insert in the epidermis on the inner surface of the epidermal end (see Japanese Patent Publication No. 63-39406). is there.

[0005]

However, in the above solution, there is an inconvenience that the insert or the outer skin has to have a special shape, and in the case where the insert has to be separated from the end of the epidermis. Was not effective. Furthermore, some foam-molded products do not have an insert built-in, which is not an effective method for such foam-molded products. Therefore, the present invention does not require the insert and the skin to have a special shape, and also provides a manufacturing method capable of easily preventing the skin terminal from collapsing even when manufacturing a foam-molded article with a skin without using the insert. Is.

[0006]

In order to achieve the above object, the present invention provides a cavity of a mold with a skin having a predetermined shape, and injecting a liquid foaming raw material into the skin to foam the skin integrally with the skin. In the method for producing a foam-molded article with a skin by, a magnet is embedded in advance in the vicinity of the skin end of the cavity surface, and when a skin device is used, a magnetically responsive body such as an iron piece is inserted into the skin, and The liquid foaming raw material is foamed while being attracted to the magnet and the magnetic force responding body pressingly holds the skin end against the cavity surface. The term "magnetic force responding body" in the present invention means one that is attracted by a magnetic force.

[0007]

The magnetic force responsive body placed in the skin is attracted to the cavity surface from the inside of the skin by the magnet embedded in the portion of the cavity surface adjacent to the skin end, and presses and holds the skin end to the cavity surface. As a result, the skin end is prevented from collapsing, and the liquid foaming raw material is foamed in the skin without leaking between the skin end and the cavity surface to form a desired foam-molded product with skin.

[0008]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a cross-sectional view of a molding die used in an embodiment of the present invention, taken along the line AA in FIG. 2, and FIG. 2 is a foam-molded article with a skin manufactured by using the molding die. Is a perspective view seen from the back side, and FIGS. 3 to 5 are sectional views showing a foam-molded article with a skin manufactured using the molding die of FIG.

First, a foam-molded article 22 with a skin manufactured according to an embodiment of the present invention will be described. The foam-molded article with skin 22 is made by contacting the foam 24 made of urethane foam, the plastic skin 26 integrally attached to the foam covering the entire front and back edges thereof, and the inner surface of the skin terminal 26a. And a magnetic force responsive body 28 made of an iron wire embedded in the foam body 24.

The outer skin 26 is of a bag shape having an opening on the back side, and the outer skin edge 26a at the periphery of the opening covers the back surface edge of the foam 24. The outer skin 26 may be made of a material other than plastic, such as a material having a foam or a plastic film attached to the back surface of the fabric, which is normally impermeable to the liquid foaming raw material. On the other hand, the magnetic force responding body 28 may be any one as long as it is attracted to the magnet, and is composed of a plate-shaped iron piece in addition to the iron wire in this embodiment, or a plastic or rubber piece in which iron powder or the like is kneaded. Can be used as appropriate. Further, the magnetic force responding body 28 may be a series of squares or circles surrounding the skin opening depending on the shape of the foamed article with the skin or the like, but if it is composed of a plurality of independent ones as in this embodiment, The degree of freedom and lightness are increased. Incidentally, in the figure, a cross indicates a position corresponding to the magnet embedded in the cavity surface of the molding die described later.

As shown in FIG. 1, the molding die 30 used to manufacture the foam-molded article 22 with skin has an upper die 30.
a, a middle mold 30b, and a lower mold 30c, and a cavity 32 having a product shape is formed inside, and a predetermined number of magnets 36 are provided on a predetermined portion of the cavity surface 34, and eight magnets in this embodiment. It is buried. The embedded position of the magnet 36 is a cavity surface to which the end of the skin 26 installed in the cavity 32 comes close when manufacturing a foam-molded article with skin to be described later. In this embodiment, it corresponds to the mark X in FIG. It is used as a cavity surface. The magnet 36 is not limited to a permanent magnet and may be an electromagnet.

Next, a method of manufacturing the foam-molded article 22 with the skin will be described. First, as shown in FIG.
Then, the skin 26 that has been previously formed by injection molding, slush molding, sewing or the like is installed in the cavity 32. At that time, the molding die 30 may be heated to a predetermined temperature by blending a liquid foaming raw material to be injected into the cavity later, in this embodiment, a urethane foam raw material. As shown in FIG. 2, the outer skin 26 has a bag shape with an opening on the back side. When the outer skin 26 is installed in the cavity 32, the outer skin end 26a on the periphery of the opening is located near the embedded magnet 34 on the cavity surface. There is. The end 26a of the skin 26 installed in the cavity 32 may be softened by its own weight or by the heat retained by the molding die 30 and fall into the skin 26.

Then, as shown in FIG.
A predetermined number of magnetic force responsive bodies 28 made of an iron wire having a length of 2.0 mm and a length of 100 to 200 mm are put in four skins 26 (two of which are not shown in FIG. 4) in the present embodiment, and each skin 2
The inner skin end 26a is pressed and held on the cavity surface 34 by being attracted to the embedded magnet 36 on the cavity surface from the inside. As a result, the skin terminal 26a is held on the cavity surface 34 without falling into the skin. The number, shape, material and the like of the magnetic force responding bodies 28 are appropriately determined according to the shape and the like of the foam-molded product with the skin as described above.

Then, as shown in FIG. 5, a liquid foaming raw material 38 made of a urethane foam raw material is injected into the outer skin 26, and is foamed integrally with the outer skin 26 with the molding die 30 being closed.
At that time, since the skin end 26a is pressed and held by the magnetic force responding body 28 on the cavity surface 34, the skin end 26a
A gap is unlikely to be formed between the cavity surface 34 and the cavity surface 34, and the liquid foaming raw material is foamed in the skin without almost leaking out of the skin, and the foamed molded article 22 with skin shown in FIG. 2 is formed. After that, the molding die 30 is opened and the foamed molded article 22 with the skin shown in FIG. 2 is taken out.

In the above description, only the production example of the foam-molded product with the skin without the insert is shown, but the present invention is not limited to this, and the foam-molded product with the skin with the insert is built-in. Is similarly applicable.

[0016]

As described above, the method for producing a foam-molded article with the skin of the present invention is such that the magnetic force responding body is attracted by the magnet on the cavity surface from the inside of the skin to hold the skin end on the cavity surface while the liquid foaming raw material is produced. Since foaming is performed, even when manufacturing a foam-molded product with a skin that does not include an insert,
It is possible to easily and reliably prevent the skin end from falling down, and prevent the liquid foaming raw material from leaking out due to the skin end falling down. Therefore, it is possible to reduce the stain on the outer surface of the molded product and the lack of thickness of the internal foam due to the leakage of the liquid foaming raw material, and it is also possible to eliminate or simplify the work of removing the burr that is caused by the curing of the leakage raw material.

Further, according to the present invention, since the magnetic force responding body such as a wire is embedded in the foam body in contact with the inner surface of the skin, there is an effect that the obtained foamed article with the skin is reinforced by the magnetic force responding body inside. ..

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a molding die used in an example of the present invention.

FIG. 2 is a perspective view of a foam-molded article with a skin manufactured by using the foam molding die of FIG. 1, viewed from the back side.

FIG. 3 is a cross-sectional view showing a skin device when manufacturing a foam-molded article with a skin according to an embodiment of the present invention.

FIG. 4 is a cross-sectional view showing when a magnetic force responding body is adsorbed when manufacturing a foam-molded article with a skin according to an embodiment of the present invention.

FIG. 5 is a cross-sectional view showing after injection of a liquid foaming raw material in the production of a foam-molded article with a skin according to an example of the present invention.

FIG. 6 is a cross-sectional view showing a conventional method for producing a foam-molded article with a skin.

[Explanation of symbols]

26 Skin 26a Skin End 28 Magnetic Responder 30 Mold 32 Cavity 34 Cavity Surface 36 Magnet 38 Liquid Foaming Raw Material

Claims (1)

Claim: What is claimed is: 1. A foamed molded article with a skin is manufactured by installing a skin having a predetermined shape in a cavity of a molding die, injecting a liquid foaming raw material into the skin to foam the skin integrally with the skin. In this method, a magnet is embedded in advance in the vicinity of the skin end of the cavity surface, and a magnetically responsive body such as an iron piece is inserted into the skin when the skin is installed, and the magnet is attracted to the magnet from the inside of the skin, A method for producing a foam-molded article with a skin, comprising foaming a liquid foaming raw material while pressing and holding a skin end to a cavity surface by a body.