JPH0744980B2 - Method for manufacturing foam sheet with integrated skin - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for manufacturing a foam sheet integrated with a skin, which is used for automobile seats and the like.

(Prior Art) A method of manufacturing a skin-integrated foam sheet in which a seat cover sewn with a skin material is set in a mold, and then a foaming undiluted solution such as polyurethane is injected and integrally foam-molded inside the seat cover is known. However, the suture line may meander due to the displacement of the seat cover due to the foaming pressure. Therefore, after aligning the stitching part of the skin piece with the protruding piece of the mold and setting it in the mold so that the seat cover does not shift in the mold, while applying the vacuum suction means to the seat cover while conforming to the inner surface of the mold. A method of fixing and performing integral foaming is also described in, for example, Japanese Patent Publication No. 53-40.
No. 98 publication. However, if the seat cover is a layer of open-celled foam such as slab urethane foam on the back surface of a breathable skin material, the seat cover cannot be fixed well by the vacuum suction means as described above. It was difficult to completely prevent meandering of the suture line due to foaming pressure.

(Problems to be Solved by the Invention) The present invention solves the above-mentioned conventional drawbacks, and the seat cover is made of a breathable material, and it is difficult to fix it in the mold by the vacuum suction means. Also in this case, it is possible to perform integral foam molding without causing meandering of the suture line, and also to prevent excessive formation of an impregnated and hardened layer on the seat cover. It was completed for the purpose of manufacturing method.

(Means for Solving the Problems) The present invention is to set a seat cover, which is a bag-like sewn skin-covered piece of an open-celled foam and a thermoplastic foam laminated on the back surface of a breathable skin material, in a lower mold, The present invention is characterized in that the thermoplastic foam is densified by thermocompression molding from the back surface of the seat cover, and then the foaming undiluted solution is injected into the surface for integral foam molding.

Hereinafter, the present invention will be described in more detail with reference to the drawings.

In FIG. 1, (1) is a lower mold for foam molding, and (2) is a seat cover set on the lower mold (1).
The seat cover (2) used in the present invention is the fifth one.
As shown in the enlarged cross-sectional view of the figure, on the back surface of the breathable skin material (3) such as woven fabric or knitted fabric, an open-cell foam (4) such as slab urethane foam and polyether foam, polyester foam, etc. A thermoplastic foam (5), which is a polyurethane foam, and a skin piece laminated by a frame laminating method. Such a skin piece is cut into a sheet shape and sewn to form a bag-shaped seat cover (2). Has been done. The seat cover (2) is first set on the lower mold (1) as shown in FIG. 1, and then the press mold (6) heated to 100 to 180 ° C. is lowered to heat it as shown in FIG. Thermoplastic molding of the plastic foam (5). As a result, the density of the thermoplastic foam (5) on the surface of the seat cover (2) is reduced.
The density of the sheet cover (2) is increased to about 0.04 to 0.05 g / cm ³ to form a high density layer, and the entire seat cover (2) is made to be strong. Then, after removing the press die (6), as shown in FIG. 3, the intermediate die (7) and the upper die (8) are lowered toward the lower die (1) to clamp the end of the seat cover (2). Then, the foaming stock solution (10) of polyurethane foam is injected from the opening (9) of the upper mold (8) in a state of being set in a sheet shape to perform integral foaming molding. At this time, the foaming pressure acts on the mold, but the densified thermoplastic foam (5) on the surface of the seat cover (2) prevents meandering of the suture line of the seat cover (2). Further, the foaming undiluted solution (10) is directly injected into the surface of the seat cover (2), but the densified thermoplastic foam (5) is excessively injected into the seat cover (2). Since the impregnation is prevented, it is possible to prevent the impregnated cured layer from being excessively formed. Thus, according to the present invention, as shown in FIG. 4, it is possible to obtain a skin-integrated foam sheet having no meandering of suture lines and an excessive impregnated hardened layer.

(Effects of the Invention) As described above, the present invention makes a seat cover elastic by pre-thermocompressing a seat cover in which a thermoplastic foam is laminated on the surface inside the lower mold and vacuum suction. Even when the means cannot be used, the suture line of the seat cover has been successfully prevented from meandering due to foaming pressure, and a skin-integrated foam sheet having a good appearance can be obtained. Further, according to the present invention, since the hot-pressed high-density layer prevents excessive impregnation of the foaming stock solution, formation of an impregnated layer having an extremely large thickness due to foaming pressure is prevented, and skin-integrated foaming having good cushioning properties is formed. You can get a sheet. Therefore, the present invention is extremely significant in that it contributes to the development of industry as a method for producing a skin-integrated foam sheet that eliminates the conventional problems.

[Brief description of drawings]

1 to 3 are sectional views for explaining the manufacturing process of the present invention,
FIG. 4 is a cross-sectional view of a skin-integrated foam sheet obtained by the method of the present invention, and FIG. 5 is an enlarged cross-sectional view of a skin material of a seat cover used in the present invention. (1): Lower mold, (2): Seat cover, (3): Breathable skin material, (4): Open-cell foam, (5): Thermoplastic foam, (10) ... Foaming stock solution.

Claims (1)

[Claims] 1. A seat cover in which a piece of skin having an open-cell foam and a thermoplastic foam laminated on the back surface of a breathable skin material is sewn in a bag shape is set in a lower mold, and thermocompression molding is performed from the back surface of the seat cover. A method for producing a skin-integrated foam sheet, which comprises densifying the thermoplastic foam and then injecting a foaming undiluted solution into the surface of the foam for integral foam molding.