JPH0780854A - Production of skin integrated foamed resin article - Google Patents

Abstract

PURPOSE:To obtain a skin integrated foamed resin article enhanced in the degree of completion by forming a bag body from a flexible thin-walled skin material having a lip structure provided thereto and opening an injection port in such a state that the bag body is received in a mold to inject a foamed resin into the mold from the injection port and clamping the mold to mold the foamed resin. CONSTITUTION:A funnel 13 is inserted in the closed injection port 5 of a bag body 2 and, by inserting the funnel 13, a lip structure 8 is opened by the elastic bending of respective mouth members 7 to bring the injection port 5 to an open state. The inserted funnel 13 is used to inject a foamed resin 15 such as urethane foam into the bag body 2 received in the mold from the injection head 14 of an injection machine. When the funnel 13 is pulled out after the injection of the foamed resin 15 is completed, the injection port 5 of the bag body 2 is automatically closed by the elastic return of the lip structure 8 so as to prevent the leakage of the foamed resin and a rise in internal pressure accompanied by the foaming of the injected foamed resin 15 is added and the injection port 5 of the bag body 2 is not opened to complete molding. Therefore, a molded product incapable of confirming the injection port 5 from appearance is obtained.

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 skin-integrated foamed resin article in which a skin and a pad made of foamed resin are integrated, such as a headrest of a vehicle seat.

[0002]

2. Description of the Related Art A headrest for a vehicle seat, which is a skin-integrated foamed resin article, is conventionally shown in FIG.
It is manufactured by the method shown in FIG. That is, the headrest stay 102 is set on the bag body 101 formed of a flexible and thin skin material that serves as the skin of the headrest,
The upper mold 103, 10 for opening and closing the headrest stay 102
4 is fixed to one side, and the upper die 103 is attached to the lower die 105 to form a bag body 10.
Close the mating mold so that 1 fits.

An inlet 106 is previously opened in the portion of the bag body 101 corresponding to the mating portion of the openable upper molds 103 and 104, and one of the upper molds 103 and 104 is opened to make the injection. Insert the funnel 107 in the shape of a funnel into the mouth 106,
Using the funnel 107, a foaming resin 109 such as urethane is injected into the bag body 101 from an injection head 108 of an injection machine (not shown) (see FIG. 9). After the injection of the foamed resin 109 is completed, the funnel 107 is pulled out as shown in FIG. 10, the open upper mold 104 is closed for a curing period, and then the mold is opened and the headrest 110 molded as shown in FIG. Take out.

The headrest 110 of FIG. 11 molded as described above has a skin formed by the bag 101 and the foamed resin 1.
The foamed resin article integrated with the skin is integrated with the pad made of 09. The injection port 106 into which the resin is injected is located between the headrest stays 102 below the inconspicuous headrest 110, and is closed by the foamed resin 109.

[0005]

In the conventional manufacturing method described above, as shown in FIG. 11, the injection port 106 into which the resin is injected remains open, and this portion is formed by the foamed resin 109.
Is exposed, resulting in a problem that the finish does not look good. That is, the injection port 106 of the bag body 101 is expanded by the increase in internal pressure due to the foaming of the injected foamed resin 109, and the molding is completed with the foamed resin liquid leaking from the injection port 106. Therefore, there is a problem that the finishing process of this portion is absolutely necessary and that the unsightly appearance cannot be completely eliminated by the finishing.

Therefore, the present invention has been made in order to solve the above-mentioned conventional problems, and a problem thereof is to provide a skin-integrated foamed resin article which can obtain a skin-integrated foamed resin article having a good finish and a high degree of completion. It is to provide a manufacturing method.

[0007]

A method for manufacturing a skin-integrated foamed resin article according to the present invention, which solves the above-mentioned problems, is such that a rim portion of an injection port for injecting a foamed resin is allowed to enter the inside and A state in which a bag body is formed by a soft and thin skin material, which is provided with a lip structure capable of elastic bending to normally close the injection port in an elastically closed state, and the bag body is housed in a molding die. Then, the injection port is opened, and the foamed resin is injected into the inside from the injection port, and the mold is closed.

[0008]

According to the above-mentioned means, it is possible to inject the foamed resin by opening the injection port of the bag body by elastically bending the lip structure. After the injection of the foamed resin, the injection port of the bag body has the lip port. Due to the elastic return of the structure, the resin foam is closed so as not to leak out, and the molding is completed with the injection port closed.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, an embodiment in which the present invention is applied to manufacture of a headrest of a vehicle seat will be described with reference to FIGS. First, the bag body 2 having a shape corresponding to the design of the headrest 1 is formed by sewing using a flexible and thin skin material as shown in FIG. The bag body 2 is formed in an upside-down state, and the edges 3 and 4 of the skin material are sewn together at the central portion corresponding to the lower portion of the headrest 1. At this time, the central portion is not sewn and the injection port 5 for injecting the resin
To open (see FIG. 1).

A rim portion 6 is formed on the rim of the injection port 5 by combining the edges 3 and 4 of the skin material. Outside each edge 3, 4 of the skin material forming the lip portion 6,
The lip member 8 corresponding to the lips is formed by sticking the mouth members 7 each formed of an elastic material such as a urethane pad into a rod shape (see FIG. 2). The mouth member 7 is a urethane pad formed in the shape of a square rod in this embodiment, and these are adhered to the outside of the respective edges 3 and 4 of the skin material with a double-sided tape 7a.

As shown in FIG. 2, the inlet port 5 of the bag body 2 provided with the lip structure 8 is normally in an elastic closed state by the respective mouth members 7. The bag body 2 thus obtained is turned upside down so that the original design surface is on the outside, the headrest stay 9 is inserted, and the state shown in FIG. 3 is set. This is set in the molding die. As shown in FIG. 4, the mold is a lower mold 1.
0 and a pair of upper molds 11 and 12 that can be opened and closed with the lower mold 10.
And is set so that the injection port 5 of the bag body 2 is located at a position substantially corresponding to the mating surface between the upper molds 11 and 12.
The protruding portion of the headrest stay 9 is fixed to one upper mold 11, and the other upper mold 12 is left open.

After this, as shown in FIG. 5, a funnel 13 in the shape of a funnel is inserted into the injection port 5 of the bag body 2 which is closed. By inserting the funnel 13, the lip structure 8 expands due to the elastic bending of each port member 7, and the injection port 5 is opened. Injector using the inserted funnel 13 (not shown)
The foaming resin 15 such as urethane is injected into the bag body 2 in the molding die from the injection head 14 (see FIG. 5). Foam resin 15
After completion of the injection, the funnel 13 is pulled out as shown in FIG. 6, the open upper mold 12 on one side is closed, and after the foam curing period is set as shown in FIG. 7, the mold is opened and the mold is opened as shown in FIG. The headrest 1 formed integrally with the skin is taken out.

When the funnel 13 is pulled out after the injection of the foamed resin 15 is completed, the injection port 5 of the bag body 2 is autonomously closed by the elastic return of the lip structure 8 so that the foamed resin liquid does not leak out, and the injected foam is formed. Since the internal pressure is increased due to the foaming of the resin 15, the injection port 5 of the bag body 2 is not opened, and the molding is completed in that state. Therefore, the injection port 5 is not visible in the appearance, and there is almost no resin leakage, so that the finishing process of this part is very simple. That is, the headrest 1 having a good finish and a high degree of perfection can be obtained (see the headrest 1 in FIG. 8).

As will be apparent from the description of the above embodiment, the manufacturing method of the present invention is not limited to the production of the headrest 1 but for manufacturing a skin-integrated foamed resin article in which the skin and the foamed resin structure inside are integrated. Can be widely applied.

[0015]

As is apparent from the above description of the embodiments, according to the present invention, a skin-integrated foamed resin article having a good finish and a high finish can be obtained.

[Brief description of drawings]

FIG. 1 is a perspective view showing a bag body forming process according to an embodiment of the present invention.

FIG. 2 is a perspective view showing a step of forming a lip structure of a bag according to an embodiment of the present invention.

FIG. 3 is a completed form diagram of the bag body according to the embodiment of the present invention.

FIG. 4 is a layout view of a forming die for a bag according to an embodiment of the present invention.

FIG. 5 is an explanatory diagram showing a process of injecting a foamed resin in an example of the present invention.

FIG. 6 is an explanatory view showing a molding process of the foamed resin in the embodiment of the present invention.

FIG. 7 is an explanatory diagram showing a curing process of a foamed resin in an example of the present invention.

FIG. 8 is an explanatory view showing a step of taking out a molded product in the example of the present invention.

FIG. 9 is an explanatory view showing a manufacturing process of a conventional headrest.

FIG. 10 is an explanatory view showing a manufacturing process of a conventional headrest.

FIG. 11 is a perspective view showing a headrest manufactured by a conventional manufacturing method.

[Explanation of symbols]

 1 Headrest 2 Bag 5 Injection Port 6 Mouth Edge 8 Lip Structure 10 Lower Mold 11 Upper Mold 12 Upper Mold 15 Foam Resin

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Claims (1)

[Claims] 1. A lip capable of elastic bending, which allows an edge portion of an injection port for injecting a foamed resin to enter the inside thereof and which normally causes the injection port to be elastically closed. A bag body made of a flexible, thin-walled skin material with a structure is formed, and while the bag body is housed in the molding die, the injection port is opened, and the foamed resin is injected from the injection port to the mold closed state. A method for producing a skin-integrated foamed resin article, which is characterized in that: