JPS60234809A - Integral seat laid in one body with frame and manufacture thereof - Google Patents

Abstract

PURPOSE:To delete the complicated processes and time for fixing a frame structure by an adhesive means etc. to the lower surface of a foam (a seat bottom surface) after foaming by a method wherein the frame structure is laid under the lower surface of the foam and the edge of a skin side section is fixed to the frame structure. CONSTITUTION:Foaming polyurethane original liquid 28 is expanded in the space section 16. Expanded polyurethane is stuck to, encircled with and united in one body with the frame structure 31. When the top force 30 is opened, it leaves the frame structure 31 as a residue in the polyurethane foam 29. Then, when the middle force 12 is separated from the bottom force 13, and the bottom of the polyurethane foam 29 is projected from the upper part of the middle force 12, the polyurethane foam 29 is released from the middle force 12, the lateral skin 22 are pulled down to the sides of the polyurethane foam 29 and put over it as shown by the arrow B to fix the edges 32 of the lateral skins 22 to the frame structure 31.

Description

Detailed Description of the Invention [Technical Field of the Invention] The present invention provides a method for attaching a skin covering the top and side surfaces of the seat and a frame structure supporting the bottom of the seat to the seat body during foam molding of the seat body. The present invention relates to an integrally molded seat having an integrally embedded frame and a method of manufacturing the same.

[Prior art and its problems]

Conventionally, various methods of manufacturing seats for vehicles such as automobiles are known. One technique is to attach the upper and side surfaces of the seat skin to a mold, heat and suction the upper surface of the skin to form the mold, and pour in a foaming polyurethane stock solution to expand the foam. There is a technique in which the seat, in which the skin and polyurethane foam are integrally molded, is released from the mold after foaming is completed. Next, according to the conventional method, as shown in FIG. 1, the seat formed in this way is manufactured by placing a frame structure 5 on the lower surface of the polyurethane foam 4, inverting the skin side part 3, and The edges were attached to the frame structure.

However, the process of placing and fixing the frame structure on the lower surface of the polyurethane foam is complicated and cumbersome, and it is necessary to fix it in an accurate position using means such as adhesive bonding. Otherwise, during the fixing work, the frame structure 5
If the seat moves, it becomes difficult to work with, and if it moves out of position, the seat becomes a defective product. For this reason, conventionally, the step of seating the frame structure 5 on the lower surface of the polyurethane foam 4 was a very important step, consuming a large amount of money and a long time.

[Purpose of the invention]

Therefore, an object of the present invention is to provide an integrally molded seat in which a frame structure is integrally embedded at the same time as foam molding, and a method for manufacturing the same, which eliminates the separate process of fixing a frame structure to a foam body after foam molding. be.

Another object of the present invention is to provide an integrally molded seat and a method for manufacturing the same, in which the frame structure is attached to the lower surface of the foam at an accurate position and is free from displacement.

[Description of preferred embodiment]

Embodiments of the integrally molded seat and the manufacturing method thereof according to the present invention will be described with reference to FIG. 2 and subsequent drawings. FIG. 2 shows the stage before the start of molding of the method of the present invention, that is, a skin 11 (to be explained in detail later with reference to FIG. 3) is stretched in a mold, generally indicated by the reference numeral 10, and a frame structure 31 is attached to an upper mold 30. FIG. 3 is a longitudinal cross-sectional end view showing a temporarily fixed state.

Molding mold 101-1: lower mold 13 forming the upper surface of the seat
, a middle mold 12 corresponding to the contour of the side surface of the seat, and an upper mold 30 forming the lower surface of the seat.

A frame structure 31 to be installed on the lower surface of the seat is temporarily fixed to the inner surface of the upper mold 30. The frame structure 31 may be made of any commonly used material such as a round metal bar, pipe, wire, or thin metal plate, but when the mold 10 is closed, that is, when the upper mold 30 is in contact with the middle mold 12 It is necessary to attach it with a temporary fixing force to the extent that it will not come off from the inner surface of the upper die 30 due to impact or the like. In the illustrated example, the bent portions 3 at both ends of the frame structure 31 are attached to the convex portion 30a near the inner surface of the upper mold 30.
1a are elastically engaged and temporarily fixed. Expressing this temporary fixing method, when the seat is later foam-molded and the surface corresponding to the bottom of the seat expands to the inner surface of the upper mold 30,
The frame structure 31 is embedded or supported within the thickness of the foam and is integrally combined with the foam, and when the upper mold 30 is opened, the elastic engagement force between the convex portion 30m and the bent portion 31a is broken. , the frame structure 31 is separated from the upper mold 30 and buried and held in the bottom surface of the seat.

The upper mold 30, the middle mold 12, and the lower mold 13 form a space 16 in which the seat is foam-molded. Although not shown, pressurizing means is provided to tightly close the joint surfaces of the upper, middle, and lower molds. The lower mold 13 has a cavity 17 below it.
A plurality of ventilation holes 18 are bored at appropriate positions, and the cavity 17 is connected to a suction pump 20 through a pipe 19.
can be aspirated by other people. As shown in FIG. 2, the surface of the lower mold 13 is given a shape that corresponds to the top surface shape of the seat to be molded, but it is of course possible to give it other shapes and patterns. It is.

The first step in the method of the invention is to provide a skin 11 having a top surface and a side surface, as shown in FIG. That is, the upper surface skin 21 and the side surface skin 22 are joined in advance by sewing or welding using a welder via a joining portion 23 such as a bead. Side skin 2
2 is cut into a shape that follows the contour of the side surface of the seat.

Further, depending on the case, as shown in the figure, the meeting portions 24 may be provided at one or more locations so that both cut edges overlap each other with an appropriate width. The material of the upper skin 21 of the skin 11 is generally polyvinyl chloride resin, polyvinyl chloride film, or cloth. In the case of cloth, a resin film such as polyvinyl chloride is used as a backing material by adhesion or It must be fused or have side treatments that prevent the fabric from breathing.

As seen in FIG. 2, in the method of the present invention, the skin 11 is in a state where the upper skin 21 and the side skin 22 cover the entire lower mold 13 of the mold, and the middle mold 12 and the lower mold 13 are aligned. The upper epidermis 21 and the side epidermis 2 on the outer periphery near the surface 25.
It is attached so that the joint portion 23 of No. 2 is located (second step). At this time, as can be seen from FIG. 2, the side skin 22 of the skin 11 is turned inside out, and the surface of the skin, especially the top skin 21, is in contact with the lower mold 13. If the side surface of the seat is tapered toward the bottom of the seat, the opening surface of the side skin 22 is smaller than the outer shape of the lower mold 13, making it difficult to attach the skin to the lower mold 13. However, in such a case, by appropriately providing the abutment portion 24 shown in FIG. 3 on the side skin 22, the skin can be easily attached to the mold.

The skin can be attached to the mold in various other ways, but it is best to attach the skin to the mold by taking into account the location of the lower and middle parts of the mold, the joining position of the top and side parts of the skin, etc. Just choose the most convenient method.

After attaching the skin 11 to the mold 10 (second step) and temporarily fixing the frame structure 31 (third step), the upper skin 21, that is, the skin portion located inside the mold, is heated to a predetermined temperature. Heat (start of 4th step). This heating is performed in order to make the upper skin 21 of the skin suitably follow the surface of the lower mold 130 during vacuum suction. The method is
It is best to heat with an infrared heater or by blowing hot air.

Next, FIG. 4 is a longitudinal cross-sectional end view showing the center of the fourth step, that is, the step of injecting the foamable polyurethane stock solution. Prior to injection, first, the upper skin 21 of the skin 11 is heated to an appropriate temperature using a heater or hot air (not shown) to soften it, and then the upper skin 21 and the lower mold are heated by the suction pump 20 through the ventilation hole 18 of the lower mold 13. Gap 27 between 13 and 13 (see Figure 2)
When the air is sucked out, the upper surface skin 21 is held in close contact with the surface of the lower mold 13 in a shape that follows the uneven shape of the surface, as shown in FIG. In this state, a stock solution 28 of foamable polyurethane is injected, and the upper mold 30 is closed to cause foaming to occur within the space 16. The volume of the polyurethane increases due to foaming, and reaches the inner surface of the upper mold 30. At this time, the foamed polyurethane adheres closely to the frame structure 31 and is integrally bonded to surround it from the periphery (excluding the portion that is in close contact with the inner surface of the upper mold).

Next, as the final step, the mold 10 is opened and the foam is taken out. First, when the upper mold 30 is opened, the engagement force between the protrusion 30m and the bent portion 3ta of the frame structure 31 is determined by the engagement force between the frame structure 31 and the polyurethane foam 29 (Fig. 5).
The upper mold 30 is opened leaving the frame structure 31 as an embedded object within the polyurethane foam 29 because the integral bonding force is stronger. Next, when the middle mold 12 and the lower mold 13 are separated, the polyurethane foam 29 is in a state in which the upper surface skin 21 of the skin 11 is integrally bonded to its lower surface (the upper surface in FIG. 5), and the side surface skin 22 hangs downward ( (Figure 5 upside down)
It remains within medium size 12. When the bottom of the polyurethane foam 29 is pushed out from above the middle mold 12, the polyurethane foam 29
is released from the middle mold 12, and when it is turned upside down, the state as shown in FIG. 5 is obtained. When the side surface skin 22 is pulled down and covered with the side surface of the polyurethane foam 29 as shown by arrow B (that is, returned from the upside down state to the state shown in FIG. 3), the end edge 32 of the side surface skin 22 is attached to the frame. Structure 31
If it is fixed to , the method of the present invention is completed.

〔Effect of the invention〕

According to the present invention, the complicated process and time of fixing the υ frame structure to the lower surface of the foam (seat bottom surface) using adhesive means etc. after foam molding can be omitted, thereby reducing the number of man-hours and significantly reducing manufacturing costs. There is an effect that can reduce the amount of waste.

In addition, the position of embedding the frame structure on the bottom surface of the foam is as follows:
The temporary fixing structure on the inner surface of the upper mold allows accurate and easy positioning, so there is no misalignment during the gluing process as in conventional methods, improving quality and providing an extremely reliable integrally molded seat. .

Furthermore, since the side skin and frame structure are conveniently already attached to the seat after it has been removed from the mold, the process can then be completed by simply inverting the side skin and securing it to the frame structure. It has the advantage that seats can be manufactured easily, inexpensively, and in large quantities.

[Brief explanation of the drawing]

FIG. 1 is a longitudinal sectional end view of a seat illustrating how to attach a conventional frame. FIG. 2 is a longitudinal cross-sectional end view of a mold for explaining the second and third steps according to the method of the present invention. FIG. 3 is a partially cutaway perspective view of the epidermis formed by the first step of the method of the present invention. FIG. 4 is a longitudinal cross-sectional end view of a mold for explaining the fourth step of the method of the present invention. FIG. 5 is a longitudinal sectional end view of the seat illustrating the last step of the method of the invention. [Main symbols] 10... Molding mold 11... Skin 12... Middle mold 13... Lower mold 18... Ventilation hole (vacuum suction hole) 21... Upper skin (upper surface part) 22...・Side surface skin (side surface part) 23...Joint part 28...Foamable polyurethane stock solution 29...Polyurethane foam 30...Upper mold 31...Frame structure 32...Edge (side surface skin) ) Patent applicant Namba Press Industry Co., Ltd.

Claims (1)

[Scope of Claims] 1. A skin formed by sewing or welding the top and side parts cut to the contour of the seat at the joints before attaching them to a mold, and the top part of the skin. a foam whose upper surface is fixed by integral molding only to the back surface of the foam, and whose side surfaces are simply covered with the side surfaces of the skin after being removed from the mold; What is claimed is: 1. An integrally molded seat comprising a frame structure which is integrally embedded during molding, and the edge of the skin side surface portion can be fixed to the frame structure. 2.1) Form the skin of the seat by sewing or welding the top and side parts cut to the contour of the seat at the joint, and ++) providing vacuum suction holes to bring the top of the skin into close contact. The joint part of the skin is located near the joining part of the lower mold and the middle mold of a mold consisting of a lower mold, a middle mold placed on top of the lower mold, and an upper mold placed on top of the lower mold. 2) Attach the skin to the mold so that the upper surface of the skin is exposed inside the mold and the side surfaces of the skin are exposed outside the mold, and close the middle mold on top of the lower mold; II) Upper mold. After temporarily fixing the frame structure to the inner surface of the mold, IV) heat the upper surface of the skin in the mold, and then apply suction through the vacuum suction hole to align the upper surface with the surface of the lower mold, and heat the foamed polyurethane. Inject the stock solution into the space surrounded by the back side of the upper surface of the epidermis and the middle mold, close the upper mold, and foam the polyurethane in the entire space. The foam, in which the upper surface and the upper surface of the foam are integrally bonded and the frame structure is integrally embedded and bonded to the lower surface of the foam, is taken out from the mold, and the side surface of the skin is A method of manufacturing a one-piece seat comprising covering the sides of a foam.