JPH085074B2 - Seat body manufacturing method - Google Patents

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a manufacturing method of a seat body for vehicles and other uses, and it is easy to attach a skin material (trim cover) to a mold, and the molding shape is accurate. The present invention relates to a manufacturing method of a seat body of this kind, which is finished to a high degree and has a reduced defective rate.

2. Description of the Related Art A conventional technique for manufacturing a seat body will be described with reference to FIGS. 10 and 11.

In FIG. 10 and FIG. 11, a skin material (trim cover) 20 formed by laminating the skin 1 and the wadding 2 in advance is manufactured in advance in the shape of the seat body, and this is used as the lower mold.
Insert along the shape of the seat inside 05, fix the end of the skin material 20 to the lower mold 05, cover the upper mold 08, and inject the urethane mold raw material from the mold raw material injection port 08a of the upper mold 08. Then, the urethane mold 4 and the skin material 20 are integrally foamed to manufacture a seat body.

However, in this conventional technique, it is difficult to insert and position the skin material 20 along the inner shape of the lower die 05, and when the urethane foam 4 injected and foamed has a lack of wall or a cavity, Since the urethane mold is covered with the tongue part, it is difficult to correct, and in the case of a defect, the entire material is lost. Also, when the lower mold is hot, if the gusset is vinyl leather, this deteriorates due to heat.

Further, although a part of the shape of the lower mold 05 is omitted in FIG. 10, as shown in FIG. 11, when the lower mold 05 has a lower mold convex portion 05a, the outer skin 1 and the wadding 2 are separated from each other. In order to obtain a shape in which the skin material 20 formed by laminating is accurately molded along the lower die convex portion 05a, the pressure is low only by the foaming pressure of the urethane mold 4, so the shape shown by the broken line in FIG. Becomes The conventional technique has a drawback that a sharp corner cannot be formed when the lower die 05 has a complicated shape as in this example.

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention The present invention solves the problems of the above-mentioned conventional techniques, and the attachment of the skin material to the mold is accurate and easy, the molding shape is accurately finished, and the defect rate can be reduced. It is intended to provide a manufacturing method of a seat body.

Means for Solving the Problems The present invention employs the following means in order to solve the above problems. That is, in the manufacturing method of the seat body,
While attaching the skin material of the seat body consisting of the skin and the wadding to the open surface of either the lower mold or the upper mold,
The gusset portion of the skin material is attached to the lower mold or the upper mold by protruding to the outside, and after heating the skin material, pressure is applied between the lower mold and the upper mold by pressure forming or vacuum forming or a combination thereof, and then, Urethane mold is foam-molded on the molded one,
It is used as a seat body.

Action According to the above means, since it is a method of attaching the skin material to the open surface of either the lower mold or the upper mold, as compared with the conventional method of mounting the skin material along the inner shape of the lower mold, Installation of the skin material on the mold is accurate and easy, and also
By pressing the skin material with the upper mold or the lower mold, or by the pressure of vacuum molding, the molded shape can be finished accurately. Further, since the gusset portion of the skin material is attached to the outside of the lower die or the upper die, the gusset portion is not heated during heating and is not affected by urethane foaming.

Embodiment Next, an embodiment of the present invention will be described in detail with reference to FIGS. 1 to 9.

First, as shown in FIG. 1a (a cross-sectional view showing a state where the skin material is attached to the lower mold) and FIG. 1b (a partial cross-sectional view of the skin material),
The skin material 20 formed by laminating and bonding the skin 1 and the wadding 2 is cut and manufactured into a seat body having the gusset 3 and is inverted and attached to the open surface of the lower mold 5. The lower mold 5 has a shape symmetrical to the seat body seating surface shape.

Next, a skin material 20 composed of the skin 1 and the wadding 2 described above.
Is heated by the heater 6 as shown in FIG.
At this time, since the gusset portion 3 is attached to the outside of the lower die 5 so as to be protruded and is on the side, it is not heated.

Next, as shown in FIG. 3a, the upper die 7 presses the skin material 20 composed of the skin 1 and the wadding 2 to form a desired seat surface shape.

Next, as shown in FIG.
Placed on the top of the mold, the mold raw material is injected through the mold raw material inlet 8a of the upper mold 8 and the foam is completed.
Pull up.

Next, the skin material 20 is attached to the town portion 3 and the urethane mold 4
At the same time, the seat body is taken out from the lower mold 5 in FIG. 4, the gusset portion 3 shown by the broken line in FIG. 5 is turned upside down, and the urethane mold 4 is covered to complete the seat body.

The above is the basic manufacturing method of the present invention. Next, application examples of the manufacturing method will be described.

When the skin material 20 composed of the skin 1 and the wadding 2 has a large elongation, the heating by the heater of FIG. 2 and the pressure molding step of FIG. 3a may be omitted. However, the gusset 3 is attached to the outside of the lower mold 5 as shown in FIG. 1a. Although not shown in the figure, vacuum forming may be used instead of the upper mold pressing in FIG. 3a.

Next, a method for producing a sharp molded shape will be described.

In order to form a concave groove in the skin material, the lower mold 5A is provided with a lower mold protrusion 5a as shown in FIG. 3b. In addition, the upper mold 7A is provided with an upper mold recess 7b correspondingly. Furthermore, in order to form the corner of the groove accurately and sharply,
An acute-angled corner portion 7a is provided at the lower corner portion of 7b. In this case, the upper corner portion of the lower die convex portion 5a also has a corner portion indicated by a broken line.
An acute angle portion corresponding to 7a may be provided. Further, the wadding 2 may be one that has undergone a treatment that causes thermoplasticity or thermal deformation.

Next, examples of various groove structure structures after completion of the foaming process shown in FIG. 4 are shown in FIGS. 3c, 3d and 3e. In this case, only the skin 1 (no wading 2) is used as the skin material, and the waddings 2A, 2B, 2C (wadding 2C) are separately used later.
Is pre-grooved). Then, after that, the urethane mold 4 is foamed.

The method shown in FIGS. 3c, 3d, and 3e can be applied to the cases of FIGS. 6 and 7 described later. In addition,
Although illustration is omitted, a heat-melting film is interposed between the epidermis 1 and the waddings 2A, 2B, 2C, and this is melted and adhered to the epidermis 1. A heat-meltable film may be placed between the wadding and the mold.

The method shown in FIGS. 3b, 3c, 3d, and 3e described above is a method that can accurately form not only the groove portion but also a circular shape and other corner portion shapes, although not shown.

Further, the outer skin 1 and the wadding 2c shown in FIG. 3e are preliminarily molded outside the foaming mold into a required shape by, for example, high-frequency wave, ultrasonic wave, heat press, etc., and the shape is inserted into the lower mold convex portion 5a of the lower mold 5A. To do. As a result, the positioning of the skin material (trim cover) including the skin 1 and the wadding 2c becomes accurate. The shape of the groove is not limited to that shown in FIG. 5e, but various shapes such as a two-color skin can be formed. This can be applied to the case of other examples.

Next, a method of placing a heat-fusible film on the wadding, utilizing vacuum forming, melting the film after foaming, and adhering it to the mold will be described with reference to FIGS. 6 and 7.

In FIG. 6, as shown in FIG. 1b, a skin material 20 formed by laminating and adhering a wadding 2 to a skin 1 and a heat-meltable film 9 having a good elongation, which is laminated on the skin material 20, are attached to a lower mold 5B. Place as indicated by the dashed line above. Since this lower mold 5B has a porous shape or a large number of small holes 5b, it has ventilation holes 5c.
By drawing a vacuum through the, the skin material 20 is molded along the shape of the upper surface of the lower mold 5B. In this case, it may be preheated depending on the physical properties of the materials for the skin 1 and the wadding 2. The film 9 may also be preheated. Further, instead of the vacuum forming, as shown in FIG. 3a, the upper mold 7 may be used for pressing or a combination thereof.

Next, as shown in FIG. 7, the raw material is injected from the mold raw material injection hole 8a of the upper mold 8 to foam, and after the foaming is completed,
High-temperature gas, vapor, etc. are sent from the ventilation hole 5c through the small hole 5b or the porous portion of the lower mold 5B to melt the film 9,
The wadding 2 (see FIG. 1b) of the skin material 20 and the urethane mold 4 are fused. At this time, a large number of small holes may be formed in the film 9 by high-temperature and high-pressure gas vapor, or small pieces or fine fractures may be made to melt to improve the air permeability of the wadding 2 and the mold 4. The film 9 can also be melted by heating the foaming heat of the urethane mold 4 and the lower mold 5b.

In the embodiment shown in FIGS. 6 and 7, the heat-meltable film 9 was placed on the skin material 20 later.
You may use what laminated | stacked this heat-meltable film 9 on the surface material 20 beforehand. Alternatively, a three-layer laminate up to wadding may be used. Further, as the skin material 20, it is possible to use a material which is made of only the skin 1 without using the wadding 2, or a material in which the skin 1 and the wadding 2 are not preliminarily laminated and the heat-meltable film 9 is interposed therebetween.

Further, as a modified example of FIG. 6, pressing with the upper mold 7 shown in FIG. 3 has been described above, but in this case, the skin 1 and the wadding 2 are not preliminarily laminated as the skin material 20, and in between. The film 9 may be used, and after the foaming treatment, the film 9 may be melted by the introduction of the high temperature gas described with reference to FIG. 7, and the skin 1 and the wadding 2 may be bonded.

The use of the heat-fusible film in the adhesion of the skin material and the wadding has been described above, but as another method, the adhesive may be applied by spraying, or the wadding may be laminated on the frame. Alternatively, a heat-fusible powder (for example, nylon-based) may be sprinkled on the surface of the skin or the wadding, and if necessary, may be temporarily fused to prevent the powder from scattering. The powder is fused by the mold temperature at the time of foaming and the foaming temperature.

Also, if the urethane undiluted solution is injected into the wadding or directly into the skin, it will be impregnated and hardened, so to prevent impregnation, place a heat-fusible film in the urethane shape or spray the above heat-fusible powder to Fill the bubbles of the wadding (urethane) to prevent or minimize the penetration of urethane. Both the powder and the film are melted after foaming by the heat and mold temperature during urethane foaming, and the air permeability with the mold is maintained.

Alternatively, in the case of high pressure and high speed, the above heat-meltable film, adhesive and powder are not used. . The reason is that, due to the high speed, the foaming is completed before almost impregnating the urethane raw material or the skin and the wadding. The above-mentioned various methods can be determined in consideration of the specifications of the seat body and the like.

Next, when the mold raw material inlet 8a in FIG. 4 is omitted, the upper mold 8 and the lower mold 5 are turned upside down. This may be turned upside down in FIGS. 1 to 3 or inverted in FIG. Then, the mold raw material is injected into the upper mold 8 (lower mold), and the lower mold 5 (upper mold) is lowered to bring the two molds together. Alternatively, the upper and lower molds 8 shown in FIG. 4 may be cut in the X-X line to form a triple structure of a lower mold and an upper mold, instead of being turned upside down as described above.

Next, items omitted in the description of the examples of the above drawings will be described.

First, the town part 3 is the same as the outer skin 1 and the wadding 2 which are the sewn parts, or a separate skin material, or a separate piece of fabric or vinyl leather is sewn on the sewing machine, It may be coupled at high frequencies. In the case of joining, they may be joined via a bead.

Secondly, when attaching the skin material 20 to the lower mold 5 in FIG. 1, the mounting position can be accurately determined by the bead, and this example will be described later with reference to FIG. 9a.

Thirdly, although illustration is omitted, before the foaming in FIGS. 4 and 7, the elastic body of the seat body or the elastic body with the frame is attached to the upper mold 8 to integrally foam with the skin and the mold. it can. The elastic body may be a steel spring, a cloth (woven fabric, knitted fabric, non-woven fabric, etc.), a plastic material, or the like.

Finally, a method of attaching the skin material omitted in the above-mentioned examples to the lower mold (or the upper mold) will be described with reference to FIGS. 8, 9a and 9b.

FIG. 8 shows details of a method of attaching the skin material to the lower mold in the portion A of FIG. A portion where the mating portion of the skin material 20 and the gusset portion 3 is directly joined by a sewing machine (or high frequency), that is, the sewing machine joint portion 10 is inserted into the trim positioning portion 5d of the lower die 5 to accurately determine the position. In this case, as shown in FIG. 9a, if a bead 22 is interposed between the skin material 20 and the gusset portion 3, more accurate positioning can be performed. In the case of part B of FIG. 6, the film 9 is further bonded together.

Then, in the example of FIG. 8, the support fitting 11 of the skin material 20 is set to the position shown by the rotary shaft 13. Further, in the example of FIG. 9a, the skin material 20 is pressed by the holding metal fitting 12 of the skin material 20.
The support fitting 11 may be laterally slid or moved vertically instead of being rotated by the rotary shaft 13.

Then, the upper mold 8 (or the lower mold 5) is lowered and pressure P is applied and pressed, and the urethane mold 4 is foamed in this state.

In this case, since the skin material 20 and the gusset portion 3 have the effect of the heat-resistant packing 14 with respect to the upper mold 8, the urethane mold 4 can be prevented from protruding from the upper mold 8 (or the lower mold 5). it can.

Further, in the example of FIG. 9b, in the case of hot molding, a large number of mold heating pipes indicated by reference numerals 8c, 5f and 5g are arranged in the lower mold 5 and the upper mold 8, and heating is performed by passing an electric heater inside each pipe. To do. In this case, since the cooling pipes 5e and 8b are arranged, it is possible to prevent deterioration of the bead 22 having a low melting point and the gusset portion 3 of vinyl having a low melting point due to heat. HR
In the case of (High Resilience) foam, the above pipes are used for hot water heating.

Furthermore, the flexible / releasing film shown by the dotted line in FIG. 9b
When 21 is placed on the skin material 20 up to the point R, the urethane mold 4 and the skin material 20 are not partially bonded.

Alternatively, a method may be used in which the film 21 is not used and the skin 1 of the skin 20 and the wadding 2 (see FIG. 1b) are not adhered to the point R. This also applies to other alternative embodiments. In the case of such partial bonding, other bonding methods are superior to frame laminating. By doing so, when a defect such as a cavity occurs in the urethane mold 4, the repair becomes easy. Further, it also prevents the occurrence of creases in the adhesive portion. This also applies to the embodiments shown in the other figures. In this case, the wadding may be omitted up to the point R depending on the specifications.

Next, although all the air vent holes 5h are omitted in the drawing, a large number of air vent holes 5h are opened at necessary places, so that the air vent holes 5h are interposed between the flexible / releasing film 21, the skin material 20, and the wall of the lower mold 5. By discharging the generated air to the outside of the mold, it is possible to prevent the formation of cavities that are likely to occur in the mold. The holes in the mold of the air vent hole 5h are flexible if avoiding direct contact with the urethane raw material.
Although not shown, the release film 21 and the skin material 20 are omitted.
With the vacuum pump, it can be installed accurately in the lower mold without any gaps. The air vent hole 5h can be directly applied to the embodiments shown in other figures.

EFFECTS OF THE INVENTION According to the seat body manufacturing method of the present invention described above, the following effects can be obtained.

(A) Compared with the conventional method of attaching the skin material 20 along the inside of the lower mold 05 shown in FIG. 10, the open surface of the lower mold 5 (or upper mold) shown in FIG. The method of attaching the skin material 20 is easier and more accurate to attach the skin material to the mold.

(B) By pressing the skin material with the upper mold 7 (or lower mold) shown in FIG. 3a, or by the vacuum molding pressure shown in FIG. 6, the molded shape is finished more accurately than the conventional method.

(C) Since the gusset portion 3 of the skin material 20 is mounted outside the lower mold 5, 5A (or upper mold), it is separated from the urethane. In the conventional method, since even the gusset portion is adhered to the mold, if the mold or the skin material is defective, both are defective, but in the manufacturing method of the present invention, the gusset portion or the gusset portion and the epidermis (middle portion) Since some of them are distant from each other, in the case of a defect, repair is easy, the defect rate is small, and the amount of loss is greatly reduced.

(D) By sharpening the corners,
The effect on the design is great.

(E) The single heat-fusible film 9 shown in FIGS. 6 and 7 can be used for vacuum forming, and can be melted to bond the mold to the wadding or the skin. You don't have to be prepared.

(F) Quality is improved, and man-hours for sewing and assembling can be greatly reduced.

The manufacturing method of the present invention described above is not limited to the seat body, but can be applied to, for example, vehicle interior parts (door pad, headrest, instrument panel, etc.) or furniture.

[Brief description of drawings]

Fig. 1a is a cross-sectional view showing a state in which the skin material is attached to the mold, Fig. 1b
Figure is a partially enlarged sectional view of the skin material, Figure 2 is a sectional view showing heating by a heater, Figure 3a is a sectional view showing pressure molding, and Figure 3b is a partially enlarged sectional view showing a corner. Figures 3c, 3d and
Fig. 3e is a partially enlarged sectional view showing each application example of corner molding,
FIG. 4 is a cross-sectional view showing mold injection, FIG. 5 is a cross-sectional view showing inversion of the gusset portion after foaming, and FIG.
Cross-sectional view of the method of bonding by vacuum forming, Fig. 7 is a cross-sectional view showing a method of melting the film by sending high temperature gas through the porous portion after foaming, and Figs. 8 and 9a are methods of attaching the skin material to the mold. Partial sectional views showing two different examples,
FIG. 9b is a cross-sectional view showing an apparatus provided with a cooling pipe, a heating pipe and an air vent hole as a modified example of FIG. 9a, FIG. 10 is a seat body cross-sectional view showing a conventional method, and FIG. 11 shows a groove formation by the conventional method. The partially expanded sectional view shown is shown. 1 ... skin, 2,2A, 2B, 2C ... wading, 3 ... town part, 4 ... urethane mold, 5,5A, 5B ... lower mold, 5a ...
… Lower mold convex part, 5b …… Small hole, 5c …… Ventilation hole, 5d …… Trim positioning part, 5h …… Air vent hole, 7,7A …… Upper mold, 7a…
… Corner, 7b …… Upper mold recess, 8 …… Mold upper mold, 8a
...... Mold material injection port, 9 ...... Heat-bonding film, 10
...... Sewing machine connection part, 11 ...... Support metal fittings, 12 ...... Press fitting metal fittings,
13 …… Rotary axis, 14 …… Heat-resistant packing, 15 …… Rotary axis,
20 …… skin material, 21 …… flexible / releasing film, 22 ……
Tamabuchi.

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

Claims (11)

[Claims] 1. A seat material comprising a skin and a wadding is attached to an open surface of either the lower mold or the upper mold, and the gusset portion of the skin is projected to the outside of the lower mold or the upper mold. It is a manufacturing method of a seat body in which after heating the skin material, pressurizing with a lower mold and an upper mold by vacuum molding or a combination thereof, and then foam-molding a urethane mold on the molded product. Then, in order to accurately shape the corner portion of the seat body groove portion, a method of manufacturing a seat body, characterized by using an upper mold having a projection-shaped corner portion provided at a peripheral edge of the recess portion corresponding to the groove portion. 2. A seat material comprising a skin and a wadding is attached to an open surface of either the lower mold or the upper mold, and the gusset portion of the skin is projected to the outside of the lower mold or the upper mold. It is a manufacturing method of a seat body in which after heating the skin material, pressurizing with a lower mold and an upper mold by vacuum molding or a combination thereof, and then foam-molding a urethane mold on the molded product. Then, cover the top of the skin with a heat-sealable film with a large elongation, after vacuum forming into the required shape, inject the urethane foam raw material and complete the foaming,
Contrary to the above vacuum, high-temperature high-pressure gas or steam is sent,
A method for manufacturing a seat body, characterized in that the film is melted and the wadding and the mold are adhered to each other, and the film layer is broken so as to have air permeability. 3. The seat according to claim 2, wherein a skin material formed by subjecting a skin, a wadding and a heat-fusible film to a three-layer lamination process in advance is used. How to make a body. 4. A seat material comprising a skin and a wadding is attached to the open surface of either the lower mold or the upper mold, and the gusset portion of the skin is projected to the outside of the lower mold or the upper mold. It is a manufacturing method of a seat body in which after heating the skin material, pressurizing with a lower mold and an upper mold by vacuum molding or a combination thereof, and then foam-molding a urethane mold on the molded product. Position the joint between the skin material and the gusset directly or through a bead and join it with the sewing machine or high frequency to insert it into the trim positioning section of the lower mold for accurate positioning, and hold them together with a metal fitting or support. A method of manufacturing a seat body, wherein a urethane mold is foamed while being pressed through metal fittings. 5. A seat material comprising a skin and a wadding is attached to the open surface of either the lower mold or the upper mold, and the gusset portion of the skin is projected to the outside of the lower mold or the upper mold. It is a manufacturing method of a seat body in which after heating the skin material, pressurizing with a lower mold and an upper mold by vacuum molding or a combination thereof, and then foam-molding a urethane mold on the molded product. Then, the elastic body of the seat body or the elastic body with a frame is attached to the upper mold, and these are integrally foamed together with the skin and the mold. 6. A seat material comprising a skin and a wadding is attached to the open surface of either the lower mold or the upper mold, and the gusset portion of the skin material is projected to the outside of the lower mold or the upper mold. It is a manufacturing method of a seat body in which after heating the skin material, pressurizing with a lower mold and an upper mold by vacuum molding or a combination thereof, and then foam-molding a urethane mold on the molded product. A method of manufacturing a seat body, characterized in that the skin material and the urethane mold are prevented from adhering to each other in a range that does not reach the peripheral edge portion of the skin material, that is, the central portion of the sewage portion. 7. The manufacturing method according to claim 6, wherein a flexible / releasing film is placed on the skin material, and the skin material and the urethane mold are adhered to each other where the film is present. A method of manufacturing a seat body, which is characterized in that it does not exist. 8. A seat material comprising a skin and a wadding is attached to the open surface of either the lower mold or the upper mold, and the gusset portion of the skin is projected to the outside of the lower mold or the upper mold. It is a manufacturing method of a seat body in which after heating the skin material, pressurizing with a lower mold and an upper mold by vacuum molding or a combination thereof, and then foam-molding a urethane mold on the molded product. In order to bond the skin material and the wadding and to prevent the urethane wadding from being impregnated with the urethane stock solution, sprinkle heat-sealable powder on one or both surfaces of the skin material or the wadding, and temporarily fuse to prevent scattering. The seat body manufacturing method is characterized in that it is installed in a foam mold so that only the necessary parts are fused. 9. A seat material having a seat body shape composed of only a skin is attached to an open surface of either the lower mold or the upper mold, a heat-fusible film is arranged on the open surface, and a urethane mold is attached thereto. A method for manufacturing a seat body, characterized in that after the foam molding, the film is melted so that the skin and the urethane mold are adhered to each other. 10. A seating material having a seat body shape composed of only a skin is attached to an open surface of either the lower mold or the upper mold, and a wadding is arranged on the open surface via a heat-fusible film. A method for manufacturing a seat body, wherein a urethane mold is foamed and molded, and then the film is melted to bond the outer skin and the wadding. 11. A skin material comprising a skin and a wadding is molded in advance into a required shape outside a foaming mold, and the skin material premolded in this way is molded into a foaming mold having a convex portion for holding this shape. A seat body manufacturing method characterized in that the urethane mold is foam-molded on top of it.