JPS60101012A - Manufacture of integral foamed and molded item - Google Patents

Abstract

PURPOSE:To allow a pad section to be integrally molded within a cover member with the cover member not being damaged by baffle plates and without forming any void therein, by mounting baffle plates of a resilient material to axial members such as stays that will be inserted previously into a cover member to be molded. CONSTITUTION:Stays 2 to which baffle plates 5 are mounted axially are stood and supported on brackets 7b, 7c of a base 6c, and a parison to be formed into a cover member 1 is extruded from a die head into a cylindrical shape with its lower end open. Thereafter, when the parison is secured between split molds 6a, 6b, although the cover member 1 is stretched and engages with the baffle plates 5, the baffle plates 5 are bent and deformed since they are made of a resilient material such as rubber. Then, compressed air is fed via a valve 7a into the parison and when the cover 1 is formed into a desired three-dimensional shape, the baffle plates 5 restore their original shape. Thereafter, the cover member 1 is removed from the mold 6 and is filled with a foam material 8.

Description

DETAILED DESCRIPTION OF THE INVENTION Technical Field The present invention relates to a method of manufacturing an integrally foamed molded product, in which a butt part is integrally foam-molded with a foam material inside a cover member such as a headrest.

(Technology Conventional 2) For example, in manufacturing headrests, etc.
A headrest cover is blow molded from the parison, and during the blow molding, the end side is inserted into the parison on the shaft of the stay in advance, and after blow molding, the butt part is formed by foam hardening of the foam material filled into the headrest cover. By performing IMR on the four ends of the stay shaft with the butt part, the headrest cover and the butt part are integrated to form a spatula I-rest with the stay protruding.

However, in this headrest, when the foam material expands in volume through foaming, the air that was pushed into the cover by foaming near the corners of the cover and the foaming gas that was not captured by the foam material were added to the foaming IIv. This tends to lead to the -19 condition where the product value is significantly impaired due to the formation of an empty f+, 1 part where no butt part exists.

In order to solve this problem, the applicant fixes a baffle plate made of plastic or a metal plate to an axial line member such as a stay that is inserted in advance into a cover member to be molded, and uses the baffle plate to form a foam. It was previously proposed (Japanese Patent Application No. 58-133514) that the foaming flow of the material should be forcibly moved and guided to the corner portion of the cover member. However, in this manufacturing method of integrally foamed molded products, when the force applied to the baffle plate is applied to the parting line where the corner of one member is clamped by the mold, the cover member is clamped by the mold. Since it is pulled and comes into contact with the baffle plate, there is a risk that the cover member may be scratched and broken by the corner edge of the 1-gon plate.

Disclosure of Hikari IJIJ The present invention provides a method for manufacturing an integrally foamed molded product in which a baffle plate moves and guides the foam flow of a foam material to a corner of a member without damaging the member. The purpose is to provide.

In the method for manufacturing an integrally foamed molded product according to A1, a baffle plate formed of an elastic material such as Go 11 is attached to the shaft line member of the stay shade, which is inserted in advance into the cover member to be molded. The baffle plate bends and deforms with the tension of the cover member when the mold is clamped, and then elastically restores itself when the cover member is formed into the mold, and the foam material filled into the cover member foams. First, by moving and guiding the foaming flow to the corner portion of the cover member, it is ensured that the foam hardened layer of the foam material can be integrally molded even at the corner portion.

Embodiments will now be described in detail with reference to the drawings.

In the illustrated embodiment, a case is shown in which, for example, a substantially horseshoe-shaped headrest having a cavity in the center is manufactured as an integrally foamed molded product. In this headrest, a gap 4' where the para-I section 4 does not exist is likely to be formed at the corner section 3a near the rectangular end surface of the S'/"-shaped corner 3 where the stay 2 protrudes from the cover member l. At the rising portion 3, a rectangular baffle plate 5 corresponding to the cross-sectional shape is installed on the axis of the stay 2, and the baffle plate 5 forcibly moves the foaming flow of the foam material toward the corner as described later. This baffle plate 5 is made of an elastic material such as rubber, and prevents the formation of a gap 4' by guiding the shaft member 2 such as a stay. A collar portion 5a projecting upward is provided at the opening for insertion. This collar part 5a acts to prevent the baffle plate 5 from being curved and deformed into the necessary tool 1- when the baffle plate 5 is curved and deformed during mold clamping iiv, which will be described later. The positional relationship of the portions 5a may be -1; or lower. Alternatively, the baffle plate 5 may be formed of a porous material, impregnated with a foam material, and finally hardened integrally with the pad portion.

Blow molding can be applied to mold the hendrest. The blow molding mold 6 has split molds 8 on the left and right.
It is equipped with a base 6C on which the split molds 8a and 8b are installed in four directions. The base 6C is equipped with a pulp 7a discharging compressed air in the center, and brackets 7b and 7c for arranging the stay 2 integrated with the headrest frame 2a are provided on the left and right sides of the pulp 7a, and further on the axis of the stay 2. A baffle plate 5 made of an elastic material such as rubber is attached (see FIG. 3).

Using this mold 6, first, the stay 2 with the baffle plate 5 attached on its axis is mounted with brackets 7b and 7c (r: 4
・The parison that forms the cover member 1 is extruded from the die head into a cylindrical shape with its lower end open, and placed on the base 8CJ: so that the headrest frame 2a and the stay 2 are received inside the parison. Do t. The baffle plate 5 attached to the stay 2 housed in this cover member 1 is 3 to 10+ sm larger than the planar area of the vertical edge part 3 of the headrest.
A narrower one can be used (see Figures 4 and 5). After that, the parison is clamped and fixed between the split molds 8a and 6b, but at this time, the lower end side of the parison is attached to the vertical part 3 that protrudes from the stay 2 of the headrest.
In order to form a parting line on the lower end sides of the split molds 6a and Bb, the cover member 1 is pulled by the mold clamp of the mold and comes into contact with the baffle plate 5, but the baffle plate 5
Since it is made of an elastic material such as rubber, it bends and deforms as the mold is clamped (see Figure 4). After the mold 6 is clamped and fixed, compressed air is pumped into the parison from the pulp 7a of the base 6C. At the same time that the cover member 1 having the desired three-dimensional shape is formed, the baffle plate 5 is restored to its original shape (fifth
After sealing (see figure), the mold 6 is also removed from the cover member 1 molded into a three-dimensional shape, and the foam material 8 is filled inside.

When the foam material 8 is filled, the cover member l is inverted so that the stay 2 protrudes upward, and the foam material 8 is retained inside the top of the cover member l.
(See Figure B6), the foam material 8 is foamed. Along with this foaming, the foam material 8 gradually increases in volume and
L, when it comes near the baffle plate 5, by bypassing it, tL rapidly moves in the direction of the corner of the rising part 3, and moves in the direction of the corner of the rising part 3 within the gap (see figure fjS7). ). At that time, the foaming gas can be discharged outside from the gap between the stay 2 and the headrest cover member l in which the stay 2 is inserted.
Further, a gate structure may be formed on the axis of the stay 2, or the gas may be discharged from a gas vent hole formed approximately in the center of the headrest cover member 1.

In the embodiment described above, the baffle plate 5 is inserted in advance when the cover member 1 is molded, but it may be attached to the shaft line member of the stay 2 shade after the cover member 1 is molded. Also, in this embodiment, 1°11. Although a headrest having a curved portion 3 is shown, the present invention can also be applied to molding a headrest having a general trapezoidal shape. In that case, one baffle plate is installed between each stay, and the foaming flow of the foam material can be moved and guided to each corner of the square. Furthermore, it can be applied not only to the production of headrests but also to the production of various foam molded products, and the members on which the baffle plate 5 is attached and arranged include not only those protruding from the cover member l such as stays, but also foam. A frame embedded in the material can also be used.

If the foaming flow of the foam material is forcibly moved toward the corner of the rising portion 3 along the baffle plate 5 in this way, what happens? Since the foaming gas that is easily trapped can be moved under pressure and deposited from an appropriate gas release point, it is possible to form a butt part 4 without any defective parts.

Effects of the Invention According to the method for manufacturing an integrally foamed molded product according to the present invention, when the cover member is clamped, even if the cover member comes into contact with the baffle plate due to tightening from its surroundings, the baffle plate has no elasticity. Since it is made of an elastic material such as rubber, it bends and deforms due to force/contact with the heel member, so the cover member is not damaged by the baffle plate, and there is no void inside the cover member. can be integrally molded.

4. A simple explanation of the 14th aspect 1 Figure 1 is a perspective view showing a headrest as an example of an integrally foamed molded product manufactured by the present invention, Figure 2 is an explanatory diagram showing problems in manufacturing the same headrest, Fig. 3 is an explanatory diagram of the mold used in the method according to the present invention, Fig. 4 is an explanatory diagram showing the curved deformation state of the baffle plate during mold molding, and Fig. 5 is an explanatory diagram of the baffle plate after molding. Fig. 6 is an explanatory drawing showing the state in which the foam material is filled into the cover member after molding, and Fig. 7 is a partially enlarged side view showing the foaming flow of the foam material. be.

1: cover member, 2: axis member such as Nisty, 3a: corner portion, 5: baffle plate, 6: mold, 8: foam material.

Figure 1 Figure 2 Figure 113

Claims (1)

[Claims] A board made of an elastic material such as rubber is attached to the axis line 8R material of the stay A, which is inserted in advance into the cover part to be molded. Manufacturing capability of an integrally foamed molded product V, characterized in that the foaming flow of the foam material filled inside is moved and guided to the corner portion of the cover member.