JPH0731759A - Production of insert built-in skin integrated foamed parts - Google Patents

Abstract

PURPOSE:To provide the process for production of the insert built-in skin integrated foamed parts which are finished in the aperture of a product surface to a clean state of a straight character while preventing the adhesion of a foaming raw material on the skin. CONSTITUTION:This process for production of the insert built-in skin integrated foamed parts integrally expansion-forms the skin and the insert 2 by disposing the insert 2 within the surface of a bag-shaped skin forming the slit aperture, setting the insert 2 and the skin in an expansion forming mold 6 and injecting the foaming raw material 31 into the skin from the aperture. The end edges of the skin are extended from the aperture into the skin to form a pair of tongue pieces 12 and a tubular film 4 is held between these tongue pieces 12. A planar jig 5 of the length approximately equal to the length of the aperture 11 is inserted between the tongue pieces 12 and, after the aperture is pulled straight by this planar jig 5, a funnel 7 is inserted into the tubular film 4 and the foaming raw material 31 is injected into the skin via this funnel 7 and is subjected to expansion foaming.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a foam product with a built-in insert and a built-in insert, which does not require post-treatment or the like and improves the finish.

[0002]

2. Description of the Related Art For automobile headrests, armrests, and the like, a foam-integrated surface-integrated foam product is widely used in which a foaming raw material is injected into a surface skin in which an insert is arranged and foam-molded integrally with the skin. Conventionally, two methods have been used to manufacture such a foam product with integrated skin including an insert due to the difference in the injection method of the foaming raw material. One is a method of forming an injection port 15 formed of a circular hole or the like in the skin 1 as shown in FIG. 9 and injecting a foaming raw material 31 into the injection port 15 with a funnel 7 or the like (prior art 1). The other is a method in which a slit-shaped opening 11 that also serves as an insert of the insert 2 is provided in the skin 1 as shown in FIG. 10, and the opening 11 is spread to inject the foaming raw material 31 into the skin. (Prior art 2).

[0003]

However, there are problems with any of the conventional methods. Once the injection port 15 of the prior art 1 is completed as a product, the foam material 32 inside the
Was visible and the appearance was bad (Fig. 11). For this reason, a covering cloth 9 to such an extent that the filling port 15 is hidden is sewn to the outer skin 1 in advance, and an adhesive or the like is used to cover the filling port 15 with the covering fabric 9. However, not only a post-process such as adhesive fixing was required, but also problems of defective adhesion occurred frequently.

On the other hand, according to the prior art 2, when the opening 11 is opened and the foaming raw material is injected, the foaming raw material 31 is used to cover the skin 1.
Was often soiled. Then, the setting state of the epidermis 1 becomes unstable because the opening 11 is widely opened,
Problems such as wrinkles and slit-shaped openings 11 meandering on the surface of the product have appeared. Also, the opening 11
However, there is a problem that the epidermis 1 hangs down into the cavity 64 due to the weight of the epidermis itself due to the large size of the cut end. Furthermore,
The opening 11 with a large mouth does not have a sealing function, and the foaming raw material 31 injected into the epidermis has a drawback that it leaks out from the opening 11 due to the foaming pressure.

In order to improve such a problem, for example, the invention of Japanese Patent Laid-Open No. 4-279307 has been proposed. However, only the skin dirt was improved, and defects such as the elongated slit-shaped openings 11 meandering on the product surface still remained, impairing the product appearance. As a result, the quality of the product deteriorated.

The present invention solves the above problems and requires no post-treatment or the like, and prevents the foaming raw material from adhering to the surface skin, and the opening on the product surface is finished in a neat and clean state. It is an object of the present invention to provide a method for manufacturing an insert-integrated skin-integrated foam product.

[0007]

According to the method for producing a foam-in-skin integrated product with a built-in insert of the present invention, an insert is arranged in the skin of a bag-shaped skin forming a slit-shaped opening, and the insert and the skin are foam-molded. In the method for manufacturing an integrated foam product with a built-in insert, in which a foaming raw material is injected into the epidermis through the opening and then foam-molded integrally with the epidermis and the insert, the edge of the epidermis is inward from the epidermis. Is provided with a pair of tongues, a tubular film is sandwiched between the tongues, and a plate-shaped jig having a length substantially equal to the opening length is inserted between the tongues. After stretching the opening linearly, insert a funnel into the tubular film and inject the foaming raw material into the epidermis through the funnel, or insert a foaming raw material injection nozzle into the tubular film. Foaming raw material in the epidermis It injected, characterized in that to perform the foam molding.

The term "a pair of tongues" as used herein means tongues which are divided into two parts with an opening in between. The tongues are simply divided into two or more, and two tongues facing each other. It also includes those whose sides are made into a tubular shape by stitching or the like. In "Insert a tubular film between the tongues and insert a plate-shaped jig having a length substantially equal to the length of the opening between the tongues." It does not matter whether or not it is prioritized. Of course, the tubular film and the plate jig may be arranged together between the tongue pieces.

[0009]

According to the method of manufacturing the foam body with integrated skin according to the present invention, when the plate jig is inserted between the tongues, the plate jig keeps the opening in a straight line. Then, by inserting the funnel cylinder mouth (or injection nozzle) into the tubular film sandwiched between the openings and pouring the foaming raw material into this funnel (or injection nozzle), the foaming raw material is injected into the epidermis without soiling the epidermis. it can. After injecting the foaming raw material, if the funnel (or the injection nozzle) is pulled out, the trace of the cylindrical opening (or the injection nozzle) of the funnel disappears by the plate-shaped jig, and the opening portion keeps the state of a straight letter. In this way, when foam molding is performed,
When the plate jig stretches the opening, the tongue pieces come into close contact with each other, and the foaming raw material does not leak from the opening due to the foaming pressure. If the plate-shaped jig and the tubular film are removed from the skin after foam molding, both the plate-shaped jig and the tubular film are thin, so these traces disappear cleanly due to the residual foam pressure of the foaming raw material, and the opening is , The slit line on the surface of the product is straight and has a neat finish.

[0010]

EXAMPLES The present invention will be described in detail below based on examples. (1) Example 1 FIGS. 1 to 7 show an example of a method for manufacturing an insert-integrated skin-integrated foam product according to the present invention. It is to make a fixed headrest. 1 is an exploded perspective view before inserting the plate-like jig into the skin, FIG. 2 is a sectional view taken along line XX of FIG. 1, FIG. 3 is an enlarged perspective view of the plate-like jig, and FIG. 4 is a plate-like jig. FIG. 5 is a cross-sectional view showing the state of the skin and the plate-shaped jig after the foam molding is completed, and FIG. 6 shows the state in which the skin is set in the foam molding die and the foam raw material is injected into the skin. FIG. 7 is a sectional view showing the headrest, which is a product.

The headrest, which is a foam product A with integrated skin including an insert, includes a skin 1, an insert 2, and a foam material 31.
And a foam material 32 formed by foaming and hardening. Epidermis 1
Is made of hard vinyl chloride and formed into a predetermined bag shape by slush molding. In addition to the above components, the tubular film 4 is used to prevent the foaming raw material 31 from adhering, and the plate jig 5 is used as a corrector (FIG. 1). The foaming mold 6 includes a base mold 61 and a lid mold 62, and the base mold 61 and the lid mold 62 form a product-shaped cavity 64.
Reference numeral 63 indicates a hinge, and the lid mold 62 is openable and closable with respect to the base mold 61.

Prior to the manufacture of the headrest, the tubular film 4 is attached inside the opening 11 of the skin 1. The tubular film 4 is made of polyethylene. The tube-shaped film 4 may be a tubular one in advance or a commercially available polyethylene bag having an open bottom. The opening 11 is provided in a slit-like shape at a position that becomes the bottom of the epidermis 1. The slit length of the opening 11 is long and slender so that the insert 2 described later can be easily housed in the outer skin 1.
In the opening 11, opposite skin edges are extended and bent into the skin to form a pair of tongue pieces 12, 12 (FIG. 2). The tubular film 4 is sewn to one of the tongue pieces 12 so that the tubular mouth is opened. Tubular film 4
The upper side of the upper part is projected from the bottom 13 of the epidermis by about 2 cm. Further, the lower side of the tubular film 4 is allowed to remain in the tongue piece 12. After such preparations, the headrest will be manufactured.

The manufacture of the headrest begins with the opening 11
Insert the insert 2 into the skin 1 from the
It begins with the insert 2 being placed in the epidermis such that 1 projects through the insertion holes 14, 14 (FIG. 1).
Then, the plate-shaped jig 5 is inserted between the tongue pieces 12 and 12 in the opening 11.
Insert.

Here, the plate-shaped jig 5 is one in which bent plates 52, 52 are welded and fixed to both sides of a support portion 51 as shown in FIG. The support portion 51 has a concave groove 511. Funnel 7
This is for guiding the tube mouth 71 of the. The bending plate 52 is made of a thin iron plate having a thickness of about 1.2 mm, and has a fixed portion 521 and a functional portion 5.
It consists of 22. The fixed portion 521 and the functional portion 522 are
It is in a state of being bent at an angle of about 20 degrees in a "V" shape (Fig. 4). The functional portion 522 has an elongated plate shape, and the total length L is
It is made slightly longer than the slit length of the opening 11. Therefore, when the functional portion 522 is inserted between the tongue pieces 12 and 12, the functional portion 522 makes the opening portion 11 stretched in a straight line.

When the plate jig 5 is inserted, the opening edge of the outer skin 1 is inserted into the notch grooves 5221 and 5221 provided on both side edges of the functional portion 522. Plate jig 5
Will be locked to the epidermis 1 and will not easily shift. The plate-shaped jig 5 is thus provided with the tongue pieces 12, 12
When set in between, the lower end of the function part 522 is the tongue piece 12
It stays in the tongue 12 without sticking out. Then, the inserted plate-shaped jig 5 is attached to the lower portion 121 of the tongue piece 12,
121 are closely attached (see FIG. 5).

Next, the skin 1 having the tubular film 4, the insert 2 and the plate jig 5 arranged thereon is set in the foaming mold 6 (FIG. 6). Here, by fitting the positioning holes 5211 of the plate-shaped jig 5 into the small protrusions (not shown) of the lid mold 62, the plate-shaped jig 5 can be easily and accurately set in the lid mold 62. A magnetic material (not shown) is embedded in the lid mold 62, and the fixing portion 521 is magnetically attracted.
This is for stably holding the plate-shaped jig 5 on the base mold 61. The epidermis 1 is also properly stored in the cavity 64.

Subsequently, the funnel 7 is inserted into the concave groove 511 of the plate jig 5.
The tip of the tube mouth is inserted into the tubular film 4 while applying the tube mouth 71. The cylinder mouth 71 is slid, and the tip of the cylinder mouth 71 is finally arranged in the opening 11. Then, by closing the foaming mold 6, the foaming raw material is ready for injection.

After the above operation, the foaming raw material 3 is placed in the epidermis 1.
Inject 1. The foaming raw material 31 is injected into the epidermis 1 from the injection machine 8 through the funnel 7 (FIG. 6). In the process of injecting the foaming raw material 31, even if the foaming raw material 31 drips from the funnel 7, since the mold is operated in the closed state, the epidermis 1 is not soiled. Further, since the tubular film 4 covers the tubular opening 71, even if the foaming raw material 31 stains the vicinity of the tubular opening 71, the tubular film 4 protects and prevents the foaming raw material 31 from adhering around the opening 11. To prevent.

When the injection of the foaming raw material 31 is completed, the funnel 7 is immediately removed. This is because the opening 11 is stretched in a straight line again by the plate-shaped jig 5, and the opening 11 is sealed by the close contact between the tongue pieces 12, 12. By the way, after passing through the funnel 7, the trace of the tube mouth 71 disappears immediately. Further, even if a drop of the foaming raw material 31 drips when the funnel 7 is removed, the foaming raw material 31 is accommodated in the tubular film 4 and the skin 1
Will not adhere to. In this embodiment, the foaming raw material 31 is injected into the skin 1 through the funnel 7, but the injection nozzle for the foaming raw material 31 may be directly inserted into the tubular film 4 without the funnel 7. Foaming raw material 31 to the skin 1
This is because it can be injected inside. The injection nozzle may be one that constitutes a part of the main body of the injection machine 8 or one that is connected to the injection machine 8.

Then, the process proceeds to the next foam hardening process. In the foam-hardening step, the opening 11 is already in a state where the opening 11 is closed by the plate-shaped jig 5, but the foaming pressure of the foaming raw material 31 is changed to the foaming material 32. As a result, the opening 11 is closed more strongly. Foam material 3
2 fills the cavity by tightening the tongue pieces 12 and 12 from both sides so as to close the opening 11, and prevents the foam material 32 from leaking to the surface of the skin. In particular, the structure in which the lower tongue pieces 121, 121 are in close contact with each other further prevents the foaming raw material 31 from leaking (FIG. 5).

After the foaming and curing are completed, the product demolding process is started. After removing the mold, the plate jig 5 and the tubular film 4 are removed from the opening 11. In this way, the headrest, which is the foam A with integrated skin including the insert, is completed.

Since the plate-shaped jig 5 and the tubular film 4 are both thin in the headrest thus produced, the trace shape obtained by removing these from the opening 11 is the foam material 3.
It will disappear cleanly due to the residual foam pressure of 2. Then, the plate jig 5 causes the tongue piece 12 to move to the opening 11
The outer skin 1 is surely bent at about 90 degrees, and the opening 11 is finished in a neat state in which the openings 11 are closed in a straight line (FIG. 7). As in the past, the opening 1
There is no defect that the slit of No. 1 meanders, undulates, or hangs around the slit inward of the epidermis. This is because the plate-shaped jig 5 finishes the foam molding in a state where the opening 11 is taut, so that there is no room for the above defects to enter.

Further, the foaming raw material 31 is injected through the funnel 7 after the mold is closed, and the tube mouth 71 is inserted into the tubular film 4, so that the foaming raw material 31 becomes the skin 1.
Do not stain. Even when the funnel 7 is pulled out, the foaming raw material 31 dripping from the funnel 7 is contained in the tubular film 4. In addition, the plate-shaped jig 5 is inserted between the tongue pieces 12 and 12, the opening 11 is stretched, and foam molding is performed in a state where the lower portions 121 of the tongue pieces are in close contact with each other. A sealing function is exerted, and the foam raw material 31 does not leak from the opening 11 to the surface of the skin during foam molding.

On the other hand, the plate-shaped jig 5 used in this embodiment has good operability and does not burden labor. Since the concave groove 511 of the plate-shaped jig 5 also serves as a guide for the funnel 7, the funnel 7 can be easily inserted. Further, since the plate-shaped jig 5 can be fixed to the lid mold 62, the setting property of the skin 1 on the foam molding mold 6 is improved. In addition, since the opening 11 is in a neat state after the foam molding, there is no need for post-processing for covering with a covering cloth or the like, which leads to a reduction in the number of working steps.

(2) Example 2 In this example, a plate-shaped jig 5'as shown in FIG. 8 is used in place of the plate-shaped jig 5 of the first embodiment. Long functional part 52
Two wedge-shaped projections 5221 and 5221 are formed on the lower edge of the second groove 2. The projection 5221 is attached to the tubular film 4
A method of inserting the plate-shaped jig 5 between the tongues 12 and 12 while the tube-shaped film 4 is locked by piercing both sides of the tongue 12, is adopted. With this configuration, when the plate-shaped jig 5'is set between the tongue pieces 12 and 12, the tubular film 4 is automatically set. Therefore, the step of sewing the tubular film 4 on the skin 1 can be omitted, and the labor saving is more advanced than in the first embodiment. Other configurations are the same as those in the first embodiment. Headrest manufacturing method is also skin 1
The same as Example 1 except that the work of attaching the tubular film 4 to the inside of the opening 11 is eliminated.

The present invention is not limited to those shown in the above embodiments, but can be variously modified within the scope of the present invention depending on the purpose and application. For example, the shapes, materials, etc. of the skin 1, insert 2, foam material 31, tube-shaped film 4, plate-shaped jig 5, funnel 7 are not limited to the examples. And
Not limited to headrest products, it is widely applied to foam products with integrated skin with insert. Further, the funnel 7 can be inserted into the tubular film 4 after the mold is closed. After inserting the funnel 7 into the tubular film 4, the operation of pouring the foaming raw material 31 may be started before the mold is closed. Further, a method may be adopted in which the foam molding is finished while the funnel 7 is still attached in the opening 11. If there are 7 small funnels, foam material 32
This is because it can be eliminated by the residual foaming pressure. of course,
It is also possible to insert the foaming raw material 31 into the skin by inserting the injection nozzle into the tubular film 4 without using the funnel 7.

[0027]

As described above, the method for manufacturing a foam product with a built-in insert according to the present invention not only prevents the meandering of the opening and the leakage of the foam raw material with a simple structure,
While preventing the foam material from adhering to the skin, without post-processing,
It has an excellent effect in providing high quality products, such as the appearance of the openings on the product surface can be nicely and neatly finished.

[Brief description of drawings]

FIG. 1 is an exploded perspective view of Example 1 before a plate-shaped jig is inserted into a skin.

FIG. 2 is a sectional view taken along line XX of FIG.

FIG. 3 is an enlarged perspective view of the plate-shaped jig of Example 1.

FIG. 4 is a side view of the plate jig shown in FIG.

FIG. 5 is a cross-sectional view showing a state in which a plate-shaped jig is inserted into the skin and foam molding is completed.

FIG. 6 is a cross-sectional view of a foaming mold showing a state where a foaming raw material is injected into the skin.

FIG. 7 is a perspective view of a headrest that is a product.

FIG. 8 is a perspective view of a plate-shaped jig of Example 2.

FIG. 9 is an explanatory cross-sectional view of Prior Art 1.

FIG. 10 is an explanatory sectional view of Prior Art 2.

FIG. 9 is a perspective view of a product manufactured by Prior Art 1.

[Explanation of symbols]

 1 Skin 11 Opening 12 Tongue 2 Insert 31 Foaming Raw Material 4 Tubular Film 5 Plate Jig 5'Plate Jig 6 Foam Mold 7 Funnel A Foam Product with Built-in Skin

─────────────────────────────────────────────────── ───

[Procedure amendment]

[Submission date] April 7, 1994

[Procedure Amendment 1]

[Document name to be amended] Statement

[Name of item to be corrected] Brief description of the drawing

[Correction method] Change

[Correction content]

[Brief description of drawings]

FIG. 1 is an exploded perspective view of Example 1 before a plate-shaped jig is inserted into a skin.

FIG. 2 is a sectional view taken along line XX of FIG.

FIG. 3 is an enlarged perspective view of the plate-shaped jig of Example 1.

FIG. 4 is a side view of the plate jig shown in FIG.

FIG. 5 is a cross-sectional view showing a state in which a plate-shaped jig is inserted into the skin and foam molding is completed.

FIG. 6 is a cross-sectional view of a foaming mold showing a state where a foaming raw material is injected into the skin.

FIG. 7 is a perspective view of a headrest that is a product.

FIG. 8 is a perspective view of a plate-shaped jig of Example 2.

FIG. 9 is an explanatory cross-sectional view of Prior Art 1.

FIG. 10 is an explanatory sectional view of Prior Art 2.

FIG. 11 is a perspective view of a product manufactured by Prior Art 1.

[Explanation of Codes] 1 Skin 11 Opening 12 Tongue 2 Insert 31 Foaming Raw Material 4 Tube Film 5 Plate Jig 5'Plate Jig 6 Foam Mold 7 Funnel A Foam Product with Built-in Skin

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI technical display area B29K 105: 20 B29L 31:58

Claims (1)

[Claims] 1. A bag-shaped skin forming a slit-shaped opening is provided with an insert in the skin, the insert and the skin are set in a foaming mold, and a foaming raw material is injected into the skin from the opening. Then, in the method of manufacturing an insert-embedded skin-integrated foam product, which is integrally foam-molded with the skin and the insert, a pair of tongue pieces are provided by extending the skin edge from the opening to the inside of the skin, and between the tongue pieces. After sandwiching the tubular film, a plate jig having a length substantially equal to the opening length is inserted between the tongue pieces, and the opening is stretched linearly by the plate jig, and then the funnel is inserted into the tubular film. To inject the foaming raw material into the epidermis through the funnel, or insert the foaming raw material injection nozzle into the tubular film to inject the foaming raw material into the epidermis to perform foam molding. Built-in insert characterized by Method of manufacturing a skin integrated foamed product.