JPH0717525U - Integrated foam molding - Google Patents

Abstract

(57) [Summary] [Purpose] To obtain an integrally foamed molded article having a good tactile sensation without impregnating a skin material with a foamable resin material. [Structure] A skin material 1 having a resin material coating layer 3 formed on the back surface of a breathable skin material 2 and sewn to have the shape of a final product, and the coating layer 3 side of the skin material 1. And a foamed body 6 obtained by foaming the foamable resin material injected into. With this configuration,
When a liquid or creamy foamable resin material is injected inside the skin material 1 and foamed and expanded, the foamable resin material is covered with the coating layer 3 provided on the back surface side of the skin cloth which is the product surface. It is surely prevented from being impregnated into 2, and the integral foam molded product A, which is covered with a skin cloth that is soft to the touch,
B is obtained.

Description

[Detailed description of the device]

[0001]

[Industrial applications]

 The present invention relates to an integral foam-molded product that is integrally foam-molded together with a skin material.

[0002]

[Prior art]

 Generally, seat cushions, headrests, etc. of automobile seats are required to have appropriate elasticity and a pleasant tactile sensation, so the outside of the foam formed by foaming a foamable resin material into the required shape has a good tactile feel. It is customary to wrap this with a skin material made of cloth to form this.

Then, as a method for obtaining a product including such a foam and a skin material covering the outside thereof, a skin sewn in accordance with the shape of the foam is foam-molded into a predetermined shape. Method of covering the material later, sewing the pre-formed skin material to the shape (contour) of the final product, setting the sewn skin material in the cavity of the foam mold, and applying liquid or liquid to the inside of the skin material. There is a method of injecting a creamy foamable resin material and foaming and expanding it to form a foam of a predetermined shape. Especially, the latter method is called an integral foam molding method, which can reduce the number of work steps. Therefore, it is becoming mainstream (see, for example, Japanese Patent Laid-Open No. 2-63805).

[0004]

[Problems to be solved by the device]

 However, according to this integral foam molding method, when a liquid or creamy foamable resin material is injected into the skin material made of cloth, a part of the foamable resin material is impregnated into the skin material. The skin material hardens, the foaming resin material enclosed inside the skin material loses the appropriate elasticity and softness that are its physical advantages, and the skin material itself becomes rugged. As a result, there is a problem that the tactile sensation of the product surface is impaired.

Therefore, the present invention has been made for the purpose of providing an integrally foam-molded article in which the skin material is prevented from being impregnated with the foamable resin material so that the tactile sensation of the product surface is good.

[0006]

[Means for Solving the Problems]

 In the present invention, as a specific means for solving such a problem, a skin material in which a coating layer of a resin material is formed on the back surface of a breathable skin cloth and which is sewn to have the shape of the final product And a foamed body obtained by subjecting the foamable resin material injected to the coating layer side of the skin material to a foaming treatment.

[0007]

[Action]

 According to the present invention, by adopting such a configuration, when a liquid or creamy foamable resin material is injected inside the skin material and expanded and expanded, the skin material is coated with the resin material on the back side of the skin material. Since the coating layer is provided, the coating layer reliably prevents the foamable resin material from impregnating the skin material, and therefore the foamable resin material is prevented from being impregnated on the back surface side of the skin material. The surface of the integrally foamed product formed by foaming and expansion will be covered with a skin-friendly skin cloth that is not impregnated with a resin material.

[0008]

[Effect of device]

 Therefore, according to the integrally foamed molded product of the present invention, the skin material is composed of the skin cloth and the coating layer on the back side thereof, and the foamable resin material is injected into the coating layer side of the skin material to integrally foam. Since the foam is formed by molding, and because the above-mentioned skin cloth is not impregnated with the resin material, the skin cloth that constitutes the product surface has a good feel to the touch and improves its tactile sensation. The product value as a product is enhanced.

[0009]

【Example】

 Hereinafter, the integral foam-molded article of the present invention will be specifically described with reference to the accompanying drawings.

First Embodiment FIG. 1 shows a headrest A of a vehicle seat according to a first embodiment of the present invention. This headrest A is manufactured by integral foam molding with a skin material, and a sewing skin material 7 formed by bag-like sewing the skin material 1 described later in advance to match the product shape It is set in a foaming mold (not shown) together with the core material 10 having a pair of poles 11, 11, and in this state, a liquid or creamy foaming resin material (for example, (Soft polyurethane resin) is injected, and this is expanded and expanded to form the foam 6 inside the sewn skin material 7.

Here, as shown in FIG. 3, the skin material 1 is provided with a resin material coating layer 3 on the back surface side of a breathable skin material 2 such as a knitted cloth or a woven cloth. That is, prior to the sewing process (the sewing process here includes the sewing process by the sewing machine and the fusion process by the welder), the back side of the original fabric 2 A resin solution (for example, a soft polyurethane resin) is evenly applied to a predetermined thickness (for example, 0.5 mm to 1.0 mm) and dried by hot air to form the resin coating layer 3. Then, the skin material 1 having such a two-layer laminate structure of the skin material 2 and the coating layer 3 is sewn so that the skin material 2 is on the product surface side to form the sewn skin material 7. Is.

In this embodiment, the soft polyurethane resin applied to the back surface of the surface cloth 2 is foamed and the skin layer portion 5 is formed on the surface portion thereof. However, in other embodiments, The non-foamed coating layer 3 may be formed without foaming the soft polyurethane resin.

As described above, in the headrest A formed by using the skin material 1 in which the coating layer 3 is provided on the back surface side of the skin cloth 2, in the manufacturing process, a liquid or cream-like material is formed inside the sewing skin material 7. Even if the foamable resin material is injected, since the coating layer 3 is interposed between the foamable resin material and the skin cloth 2, it is ensured that the foamable resin material is impregnated in the skin cloth 2. To be prevented. Therefore, in the headrest A as a product, since the surface cloth 2 forming the product surface is not impregnated with the foamable resin material, the soft and comfortable material state is maintained as it is. As compared with the case where the surface cloth 2 is cured by impregnation with a resin material, the surface cloth 2 is soft to the touch, and the foamable resin material included in the surface cloth 2 has a proper degree of inherent property. Since the elasticity and softness are maintained well, the tactile feel of the headrest A is improved, which in turn enhances the commercial value of the headrest A.

Second Embodiment FIG. 2 shows an armrest B as an integral foam molded article according to a second embodiment of the present invention. Similar to the headrest A, the armrest B also has a sewn skin material 7 formed by sewing a skin material 1 having a coating layer 3 on the back surface of the skin cloth 2 and a foaming type with a core material 12 arranged therein. The foamed resin material is obtained by injecting a foaming resin material into the sewing skin material 7 and expanding and expanding the foaming resin material. Therefore, also in this armrest B, since the coating layer 3 is interposed between the foamable resin material and the skin cloth 2 at the time of injecting the foamable resin material, the foamable resin material to the skin cloth 2 is It is possible to obtain an armrest B having a surface that is soft to the touch and is not impregnated.

In addition to the headrest A and the armrest B in which the sewn skin material 7 is formed into a bag shape as in each of the above-mentioned embodiments, the integrally foamed molded article of the present invention has a sewn skin material 7 such as a seat cushion. Needless to say, the present invention can be applied to an opening shape.

[Brief description of drawings]

FIG. 1 is a partial sectional perspective view of a headrest according to a first embodiment of the present invention.

FIG. 2 is a partial sectional perspective view of an armrest according to a second embodiment of the present invention.

FIG. 3 is a perspective view showing a structure of a skin material.

[Explanation of symbols]

1 is a skin material, 2 is a skin cloth, 3 is a coating layer, 4 is a foam layer portion, 5 is a skin layer portion, 6 is a foam, 7 is a sewing skin material, 10 is a core material, 11 is a pole, and 12 is a core. Material, A is a headrest, B is an armrest.

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Claims (1)

[Scope of utility model registration request] 1. A skin material having a resin material coating layer formed on the back surface of a breathable skin material and sewn to have the shape of the final product, and the skin material is injected into the coating layer side. An integral foam-molded article comprising a foamed body obtained by foaming a foamable resin material.