JPH11207060A - Skin integrated foaming product and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce a production cost and to improve quality. SOLUTION: After housing fibrous crushed products 7 (step S2) in a space part 3 consisting of a skin member 1, an urethane material 4 is poured (step S3) into the part 3. The material 4 of low in viscosity just after pouring is easily absorbed to the fibrous crushed products 7 without being impregnated to the member 1 and the quality of a head rest 5 is improved. As the impregnating of urethane to the member 1 is suppressed without using a film (backing material), not only the member 1 but also a product is made inexpensive. At the time of foaming the material 4 (step S4), the products 7 are dispersed with the material 4 in the part 3, a core material is uniformed and a quality is improved by this portion. A recycled material can be used for the products 7 to save resources by this.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foamed product integrated with a skin used for a headrest of an automobile and a method for producing the same.

[0002]

2. Description of the Related Art As an example of a conventional method for manufacturing a headrest, urethane foam as a core material is molded (that is, molded urethane foam [urethane foam molded in a mold] is obtained), and then molded in advance. There is a method of covering the urethane foam with a skin member. In this case, as the skin member, a member composed of one layer of woven fabric (woven fabric) or a member composed of two layers of woven fabric and slab urethane foam is used. The urethane molded by injecting the raw material into the mold is called mold urethane, whereas urethane foaming in an open system (slab urethane,
Slab urethane foam).

[0003] In contrast to the headrest manufacturing method described above,
There is a method of injecting a urethane foam raw material as a core material into a space formed by a skin member, foaming the urethane, and integrally molding the core material and the skin member (a method of manufacturing a skin integral foamed product). This method can reduce costs,
In addition, since it has an advantage such as an increase in the degree of freedom of design, it has recently been widely used.

[0004] A method of manufacturing the skin-integrated foam product will be described with reference to FIG. First, the skin member 1 is set in the mold 2 (step S10), and a urethane raw material (urethane foaming raw material) 4 as a core material is injected into the inside (space portion) 3 of the skin member 1 (step S11). The foam molding of step 4 is performed and cured (cured) (step S12), the mold 2 is opened and removed from the mold to obtain an integrally molded headrest (skin integral foamed product) 5 (step S13).
). In the integrated molding method shown in FIG. 2 described above, as shown in FIG. 3, a urethane raw material (urethane foam raw material) 4 impregnates the skin member 1 and the surface of the headrest 5 (skin member 1).
There is a problem that urethane exudes from the rubber or unnecessary curing of the skin member 1 (the target portion is indicated by reference numeral 5a). In FIG. 3, reference numeral 6 denotes a fixing bracket.

In order to solve the above problem, as shown in FIG. 4, a film (backing material) 1c is further attached to a two-layer member of one layer of woven fabric 1a and one layer of slab urethane foam 1b. There is a case where the skin member 1 composed of three layers is formed, and the impregnation of the urethane raw material 4 is suppressed by the film 1c. In order to solve the above problem, the skin member 1 is composed of two layers of one layer of the woven fabric 1a and one layer of the slab urethane foam 1b, and the slab urethane foam 1b is made thicker or denser. It is conceivable that.

[0006]

In the case where the headrest 5 is integrally formed by using the three-layered skin member 1 as shown in FIG. 4, the manufacturing cost of the skin member 1 increases, and an appropriate remedy is taken. Couldn't be. In addition, the skin member 1
Of one layer of woven fabric 1a and slab urethane foam 1b
Even when the slab urethane foam 1b has a layered structure and the slab urethane foam 1b is thick or a slab urethane foam 1b having a high density is used, the production cost is high and it cannot be an appropriate improvement measure.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a skin-integrated foamed product capable of reducing the production cost and improving the quality, and a method for producing the same.

[0008]

According to the first aspect of the present invention,
A skin member forming a space portion, and a resin foam material integrally injected with the skin member by being injected after a crushed product made of fiber or a crushed product made of foamed resin is stored in the space portion. It is characterized by.

According to a second aspect of the present invention, after a crushed product made of fiber or a crushed product made of foamed resin is stored in a space formed by the skin member, a resin foam material is injected into the skin member. It is characterized by.

[0010]

DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to FIG. In FIG. 1, one layer of woven fabric 1a
The skin member 1 (the skin member 1 having no film) is set in the mold 2 to form the space 3 having a shape following the outer shape of the headrest 5 (step S1). Next, the crushed product 7 made of fiber is stored in the space 3 formed by the set skin member 1 (step S2).

Subsequently, the space 3 formed by the skin member 1
A urethane raw material (resin foam material, core material) 4 as a core material is injected into the inside (step S3). At this time, the urethane raw material 4 immediately after the injection is easily absorbed by the crushed product 7 made of fiber due to its low viscosity, and is not impregnated into the skin member 1.

In the step S4 following the step S3, the urethane raw material 4 is subjected to foam molding to fill the space 3 formed by the skin member 1. At this time, the fiber crushed product 7
Is the inside of the skin member 1 together with the urethane raw material 4 (space portion 3)
It is dispersed in. In this step S4, a curing process is performed. Subsequent to step S4, the mold 2 is opened to release the mold, and the integrally formed headrest 5 (skin integral foam) is obtained (step S5).

The crushed product 7 made of fiber does not need to be new, and may be a cut material of the skin or a recycled material of the sheet skin. The material of the crushed product 7 made of fiber is
Although not particularly limited, the fiber length is desirably less than 30 mm.

According to the present embodiment, after the crushed product 7 made of fiber is stored in the space 3 formed by the skin member 1 (step S2), the space 3 formed by the skin member 1 is removed. Then, urethane raw material 4 (resin foam) is injected (step S3). For this reason, the urethane raw material 4 having a low viscosity immediately after the injection is easily absorbed by the crushed product 7 made of fiber, and is not impregnated into the skin member 1, so that the quality of the headrest 5 (skin integrated foam) can be improved.

Further, since the impregnation of the urethane into the skin member 1 can be suppressed without using the film 1c (backing material), the cost of the skin member 1 and the product can be reduced. Further, at the time of foam molding of the urethane raw material 4 (Step S4), the fiber crushed product 7 is dispersed in the space 3 together with the urethane raw material 4, so that the core material can be homogenized and the quality can be improved accordingly. In addition, the above-mentioned fiber-made crushed product 7 is not new, and even if a recycled material is used, the above-described function is exhibited, so that resource saving can be achieved.

The present applicant has reported that the fiber length is 5, 15, 30 mm.
When the impregnating property and the dispersing property were examined with respect to the crushed product 7 which was the above, the results shown in Table 1 were obtained. Here, the skin member 1 to be tested is a one-layer woven fabric 1a (without the slab urethane foam 1b and the film 1c) and a 4% w (relative to the urethane raw material 4 [core material]) fiber crushed product 7 in the space. It was stored in part 3 and tested. According to the data of Table 1, according to the present invention,
Even if the skin member 1 (the skin member 1 having no film) is made of the single-layer woven fabric 1a, the impregnation of the urethane raw material 4 is suppressed, and the headrest 5 (skin-integrated foam) of good quality can be obtained. As a result, the production cost can be reduced due to the absence of the film, and the urethane raw material 4 is well dispersed in the space 3 of the skin member 1, thereby improving the quality of the headrest 5 (skin-integrated foam). I was able to confirm that it could be achieved.

[0017]

In the above embodiment, the case where the skin member 1 is a single-layer woven fabric 1a has been described as an example. Instead, the skin member 1 having two layers of the woven fabric 1a and the slab urethane foam 1b is used. May be used. In this case, as described above, the urethane raw material 4 is easily absorbed by the crushed product 7 made of fiber, and is not impregnated into the skin member 1.
It is not necessary to use a thick or high-density slab urethane foam 1b. Therefore, the cost can be reduced as compared with the case where the skin member 1 having the slab urethane foam 1b which is made thick or has a high density in order to suppress impregnation is used.

In the above-described embodiment, the case where the crushed product 7 made of fiber is used as an example, but a crushed product made of foamed resin (reference numerals omitted) may be used instead. The pulverized product made of the foamed resin does not need to be new, and may be a recycled material. The material of the pulverized product made of foamed resin is not particularly limited, but it is preferable that the particle size is less than 5 mm.

In the case of using a foamed resin pulverized product,
After the pulverized product made of foamed resin is stored in the space 3 formed by the skin member 1 (see step S2), the skin member 1
Since the urethane raw material 4 (resin foam) is injected into the space 3 formed by the step (see step S3), the urethane raw material 4 having a low viscosity immediately after the injection is easily absorbed by the pulverized product made of foamed resin. In addition, the quality of the headrest 5 (skin-integrated foam) can be improved without being impregnated into the skin member 1.

Further, since the urethane raw material 4 is easily absorbed by the pulverized product made of the foamed resin and is not impregnated into the skin member 1, the slab urethane foam 1b of the skin member 1 has a large thickness or a high density. You don't have to use expensive ones. Therefore, the cost of the skin member 1 and the headrest 5 can be reduced. further,
At the time of foam molding of the urethane raw material 4 (Step S4), the pulverized product made of the foamed resin is dispersed in the space 3 together with the urethane raw material 4, so that the urethane raw material 4 can be homogenized, and the quality can be improved accordingly. In addition, the above-mentioned foamed resin pulverized product is not new, and even if a recycled material is used, the above-described function is exhibited, so that resource saving can be achieved.

The present applicant examined the impregnating property and dispersibility of a crushed product made of urethane (foamed resin) having a particle size of 1 mm and 5 mm. The results shown in Table 2 were obtained. Here, the skin member 1 to be tested includes one layer of woven fabric 1a and one layer of slab urethane foam 1b (2 mmt, 20 kg / m2).
³ ) consisting of two layers, 8% w (urethane raw material 4)
A urethane (foamed resin) pulverized product (with respect to the [core material]) was placed in the space 3 and tested. According to the data of Table 2, according to the present invention, impregnation of the urethane raw material 4 into the skin member 1 is suppressed, and a high-quality headrest 5 (skin-integrated foam) can be obtained, and the production cost can be reduced. And,
If a pulverized product made of urethane (foamed resin) having a particle size of 1 mm is used, the urethane raw material 4 (core material) is well dispersed inside the skin member 1, thereby improving the quality of the headrest 5 (skin-integrated foam). Could be confirmed.

[0023]

[0024]

According to the first aspect of the present invention, a crushed product made of fiber or a crushed product made of foamed resin is housed in a space formed by a skin member, and then injected and injected together with the skin member. Is integrally molded, the resin foam having a low viscosity is easily absorbed by a crushed product made of fiber or a crushed product made of foamed resin, and is not impregnated into the skin member, so that the quality can be improved.

According to a second aspect of the present invention, after a crushed product made of fiber or a crushed product made of foamed resin is stored in the space formed by the skin member, the resin is placed in the space formed by the skin member. Since the foaming material is injected, the resin foaming material having a low viscosity immediately after the injection is easily absorbed by the crushed product made of fiber or the crushed product made of foamed resin, and is not impregnated into the skin member. Quality can be improved.

In addition, since the impregnation of the resin foam material into the skin member can be suppressed without using a film (backing material), it is possible to reduce the cost of the skin member and the product. Furthermore, when foaming the resin foam material, the crushed fiber product is dispersed in the space together with the resin foam material, so that the resin foam material can be homogenized and the quality can be improved accordingly. Also,
The crushed product made of fiber or the crushed product made of foamed resin is not a new one, and the above-mentioned function is exhibited even by using a recycled material. Therefore, resource saving can be achieved by using the recycled material.

[Brief description of the drawings]

FIG. 1 is a manufacturing process diagram schematically showing an embodiment of the present invention.

FIG. 2 is a manufacturing process diagram schematically showing an example of a conventional method for manufacturing a skin integral foam.

FIG. 3 is a diagram schematically showing a problem of the manufacturing method of FIG. 2;

FIG. 4 is a sectional view showing an example of a skin member having three layers.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Skin member 3 Space part 4 Urethane raw material 7 Fragment made of fiber

Claims (2)

[Claims] 1. A skin member forming a space portion, and a resin foam material integrally formed with the skin member by being injected after a crushed product made of fiber or a crushed product made of foamed resin is stored in the space portion. And a skin-integrated foam product. 2. A skin integral, wherein after a crushed product made of fiber or a crushed product made of foamed resin is stored in a space formed by the skin member, a resin foam material is injected into the skin member. Manufacturing method for foamed products.