JPH07223226A - Manufacture of facing-integrated foam - Google Patents

Abstract

PURPOSE:To use an existing sewn part as an opening for resin injection and core material insertion and prevent an appearance from becoming unpresentable and a touch feeling from becoming unpleasing. CONSTITUTION:A first skin 10 and a second skin fitted to an intermediate skin and folded back at a stitched sewn part are provided and an opening 12 consisting of a non-sewn part is formed on a part of the sewn part. In addition, a first replicated part 13 and a second replicated part 14, both being positioned facing against each other, are provided in the opening. A bag-like skin body 1 has the above constitution and is arranged in a molding die 2. Further, an injection nozzle 4 is inserted into the opening 12 and a specified amount of foaming resin is injected into the molding die 2. After that, the resin is allowed to foam into a molding in a state that the first replicated part 13 is pressed into contact with the first skin 10. Thus it is possible to prevent an unfilled part from remaining between the first replicated part 13 and the first skin 10, and manufacture a foamed product having a presentable appearance and a pleasing feeling.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is used in the manufacture of headrests for automobile seats and the like, and a substantially bag-shaped skin is placed in a molding die, and a foamed resin is injected into the skin to form a foam-integrated skin. Manufacturing method.

[0002]

2. Description of the Related Art An automobile headrest is formed of a foamed molded product having a core material inside and a surface covered with a skin. As a method of manufacturing this headrest, a method in which a foamed molded body is formed and then a separately formed skin body is covered is generally used. However, if the number of man-hours required for covering is large, deformation occurs during covering. Therefore, in recent years, a method of arranging a bag-shaped skin member in a molding die and integrally foam-molding the same has become mainstream.

In the case of an armrest or the like, there is no suitable place for providing an injection port due to design problems.
A manufacturing method in which a foamed molded body and a skin body are formed and then covered and sewn is performed. In the manufacturing method of foaming integrally with the skin, a bag-shaped skin body formed in advance by sewing or the like is first placed in a molding die. At this time, generally, a reinforcing core material is put inside the skin. Then, a foamed resin is injected into the epidermis, the injection port is closed, and foam molding is performed. The foamed resin is foamed to increase its volume, and the pressure causes the epidermis to be pressed against the mold surface to be shaped and filled in the epidermis. Therefore, it can be said that this is an excellent manufacturing method because the number of steps is small and high shape accuracy can be obtained.

By the way, in the above manufacturing method, for example, FIGS.
When manufacturing the headrest shown in FIG.
As shown in Japanese Patent No. 9307, an opening 100 for injecting a foamed resin is required in the epidermis. This opening 10
0 is also used as a core material insertion port and is generally provided at the center of the lower surface of the headrest. As a product, the opening 100 needs to be closed from the viewpoint of design.

As a method of closing this opening, as shown in FIG. 4, the opening 100 is provided with a pair of folded-back portions 101 and 102 which are bent inward and face each other and abut each other. With this configuration, the folded-back portions 101 and 102 are pressed and brought into close contact with each other by the foaming pressure so as to be close to each other, and the opening 100 can be closed while preventing resin leakage from the opening 100. The length of the folded portions 101, 102 must be sufficiently long so that the foamed resin can be prevented from entering between the pair of folded portions 101, 102.

[0006]

In the conventional manufacturing method, the opening 100 is provided at the center of the lower surface of the headrest. However, in such a manufacturing method, there is a problem that the number of cutting pieces constituting the skin body before sewing is large and the number of sewing steps is large. Therefore, it is possible to use the existing sewing portion 200 of the headrest shown in FIG. 3 as the opening and the injection port. By doing so, the armrest and the like can also be formed by foaming integrally with the skin, and the number of steps can be greatly reduced.

In this case as well, the folded-back portion of the injection port is necessary, and further, the folded-back portion is sufficiently long. However, in the sewn portion 200, the outer skins (cutting pieces) on both sides of the sewn portion 200 are bent at the sewn portion 200. Therefore, at least one of the folded portions is close to one of the skins. Therefore, when foam molding is performed using such a folded back portion, as shown in FIG. 5, the tip of one folded back portion 101 is fixed in a state of abutting against the skin 103, so that the sealed space 300 is easily formed. However, there is a problem in that the filling of the foamed resin is hindered and the appearance and touch are impaired.

The present invention has been made in view of the above circumstances, and an object of the present invention is to utilize existing sewing parts as openings and inlets and to prevent appearance defects and touch feeling defects.

[0009]

A method of manufacturing a foam-in-skin integrated product of the present invention has a first skin and a second skin which are folded back by a sewn portion which is sewn in accordance with the inside surface, and one of the sewn portions is An opening formed of a non-sewn portion is formed in the portion, and has a first folded portion and a second folded portion that are opposed to each other in the opening, and the first folded portion is a bag-like skin body that is folded back so as to face the first skin. In the mold, a step of inserting an injection nozzle into the opening and injecting a predetermined amount of foamed resin into the epidermis from the injection nozzle, and a state in which the first folded portion is pressed against the first epidermis. While foaming the foamed resin and foam molding
And a step of fixing the state in which the folded-back portion is pressed against the first skin.

[0010]

The skin used in the manufacturing method of the present invention has a bag-like shape in which a plurality of skins (cutting pieces) are sewn.
The plurality of skins are sewn in accordance with the inner surface and then inverted, and the sewn ends project into the bag-shaped inside. An opening formed of a non-sewn portion is formed in a part of the sewn portion, and the opening functions as an insertion port for the core material or an injection port for the foamed resin.

Inside the opening formed of the non-sewn portion, the first folded-back portion in which the first skin is folded back and the second folded-back portion in which the second skin is folded back face each other. The first skin and the second skin form an angle, the first folded portion is folded back so as to face the first skin, and the angle formed by the first folded portion and the first skin is an acute angle. Then, in the case of having a core material, the core material is inserted into the inside of the skin through the opening, and the skin is placed in the molding die. Next, an injection nozzle is inserted into the opening, and a predetermined amount of foamed resin is injected into the epidermis from the injection nozzle.

Then, the injection nozzle is pulled out from the opening, and the foamed resin is foamed while maintaining the state in which the first folded portion is pressed against the first skin. This can be performed by pressing the pressing plate with a movable die or the like. Also the injection nozzle is the first
It is also possible to press the folded-back portion against the first skin and pull out the injection nozzle immediately before the foamed resin foams and reaches the tip of the injection nozzle. Further, it is also possible to sew the first folded-back portion and the first outer skin, or to bond them with a double-sided tape or the like.

By foaming the foamed resin in this manner, the first folded portion is fixed in a state of being pressed against the first skin. Therefore, it is possible to prevent the presence of a space between the first folded-back portion and the first skin, and to prevent the appearance and tactile sensation from being poor due to poor filling. Further, by sufficiently increasing the lengths of the first folded portion and the second folded portion, it is possible to prevent the foamed resin from leaking between the first folded portion and the second folded portion.

[0014]

EXAMPLES The present invention will be specifically described below with reference to Examples with reference to FIGS. 1 and 2. The present embodiment is an application of the present invention to the manufacture of an automobile headrest. Although not shown, the skin 1 is composed of a urethane film layer and a slab foam layer integrally laminated on the back surface of the film layer. This epidermis 1 is
It is composed of a plurality of cut skins including the first skin 10 and the second skin 11, and is formed into a bag shape by sewing.

An opening 12 consisting of a non-sewn portion is formed in a part of the sewn portion where the first skin 10 and the second skin 11 are joined. The opening 12 is formed between the first folded portion 13 in which the first skin 10 is folded back inward and the second folded portion 14 in which the second skin 11 is folded back inward.
The width of each of the folded-back portion 13 and the second folded-back portion 14 is 50 to 70 mm.

A core material (not shown) is provided in the skin 1 with an opening 1.
It is inserted from 2, and the whole is placed in the molding die 2. The mold 2 includes a pair of fixed molds 20 and 21 and a movable mold 22.
It consists of and. One end of a pressing plate 3 having a thickness of 1 mm is fixed to the upper end surface of the fixed die 20, and the other end of the pressing plate 3 is swingable. The tip of the other end is configured to project into the cavity by about 15 mm when swinging substantially at right angles to the one end.

The movable die 22 is in sliding contact with the fixed die 21 and holds the pressing plate 3 together with the fixed die 20 when the movable die 22 is driven forward in a direction approaching the fixed die 20. When the movable mold 22 is in the retracted position, the skin 1 arranged in the mold 2 has
As shown in FIG. 1, the injection nozzle 4 is inserted through the opening 12. Then, the lower end of the injection nozzle 4 presses the other end of the pressing plate 3, and the swinging of the pressing plate 3 presses the first folded-back portion 13 in a direction approaching the first skin 10.
The injection nozzle 4 is inserted until the tips are located below the tips of the first folded portion 13 and the second folded portion 14,
The foamed resin is prevented from adhering to the vicinity of the opening 12.

When a predetermined amount of the foamed resin 5 is injected from the injection nozzle 4 into the skin body 1, the injection nozzle 4 rises and is pulled out from the opening 12, and the movable die 22 advances to fix the pressing plate 3. The mold 20 is pressed and clamped (FIG. 2). In that state, the first folded portion 13 is pressed against the first skin 10, and no space is created between the first folded portion 13 and the first skin 10.

When the foamed resin 5 is foamed to fill the inside of the skin 1, the second folded portion 14 is pressed against the pressing plate 3 by the foaming pressure.
And the opening 12 is closed. This allows opening 1
It is possible to prevent the foamed resin from leaking from 2. Then mold 2
Open and remove the pressing plate 3 from the opening 12,
The folded-back portion 13 and the second folded-back portion 14 elastically contact each other by their own elastic force, and the appearance of the opening 12 cannot be seen from the appearance.

[0020]

That is, according to the method for producing a foam with integrated skin of the present invention, since the openings for inserting the core material and for the injection are provided in the sewn portion of the skin, the appearance quality is improved and the number of cutting pieces is reduced. The reduction can reduce the number of sewing steps. Further, since it is possible to reliably prevent the unfilled portion from being generated between the folded portion and the skin during foam molding, it is possible to prevent the generation of a defective product in appearance and touch.

Since an opening is provided in the existing sewn portion, an armrest or the like, which has conventionally been difficult to integrally form because it cannot be provided with an opening, can also be manufactured by skin integral foaming molding, and the number of steps is greatly reduced. be able to.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a mold and a skin body immediately before foam molding according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view of the mold and the skin-integrated foam product after foam molding in one embodiment of the present invention.

FIG. 3 is a perspective view of a headrest manufactured by a conventional manufacturing method.

FIG. 4 is a sectional view of a main part of a headrest manufactured by a conventional manufacturing method.

FIG. 5 is an explanatory cross-sectional view showing a defective portion of a foam product with integrated skin according to a conventional manufacturing method.

[Explanation of symbols]

1: Epidermis 2: Molding die
3: Pressing plate 4: Injection nozzle 5: Foam resin 1
0: First skin 11: Second skin 12: Opening 1
3: 1st folding | returning part 14: 2nd folding | returning part

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Claims (1)

[Claims] 1. A first skin and a second skin that are folded back at a sewn portion that is sewn to match the inside surface, and an opening formed of a non-sewn portion is formed in a part of the sewn portion. Having a first turn-back portion and a second turn-back portion facing each other,
A step of arranging a bag-shaped skin body whose folded-back portion is opposed to the first skin in a molding die; and inserting an injection nozzle into the opening and applying a predetermined amount of foamed resin from the injection nozzle to the skin. A step of injecting into the body, and foaming the foamed resin by foaming the foamed resin while maintaining the state in which the first folded portion is pressed against the first skin, and the first folded portion is pressed against the first skin. A step of fixing the state,
A method for producing a foam product with integrated skin, comprising: