JPS61148011A - Molding method of foam molded article having skin - Google Patents

Abstract

PURPOSE:To facilitate molding of a skin material containing a permeable sheetlike material such as cloth, by a method wherein a foamable resin material is cast through a lid mold side after molding has been performed through vacuum suction from a molding tool side while air pressure is being applied to a plastic sheet from the lid mold side. CONSTITUTION:A skin material 11 is constituted of a permeable sheetlike material 12 and a plastic sheet 13 arranged on the backside of the permeable sheet like material. The skin material 11 is held by placing the same between fringe joining parts 22, 32 of a molding tool and lid mold so that the permeable sheetlike material 12 and plastic sheet 13 are become of a molding tool 20 side and lid mold 30 side respectively. Then air pressure is applied to the plastic sheet 13 of the backside of the skin material 11 by feeding air within the mold through a hole 35 of the lid mold 30. When the air in a cavity 21 is removed by sucking the same through vacuum sucking holes 25, 25 or the molding tool 20 under this state, the titled molded article is molded by a method wherein shape retention of the skin material 11 is performed in a predetermined molded shape unitarily by adhering the skin material closely to the cavity 21. Then a foamable resin material 41 is cast through the lid mold side 30.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for forming a foam molded article having a skin, particularly a skin made of a breathable sheet material such as cloth.

For example, as a seat cushion for chairs or various interior padding materials, a skin material with a plastic sheet placed on the back side of a breathable sheet material such as cloth is used, and a foamed synthetic resin layer is integrated with this skin material. Molded products are used.

Of course, there is a method for manufacturing molded products with this kind of skin, in which the skin material and the foamed synthetic resin layer are molded separately and then the two are integrated. It goes without saying that it is most preferable that the forming of the layers be carried out simultaneously and integrally.

However, when a material including a sheet-like material such as breathable cloth is used as the skin material.

Even if a plastic sheet is disposed on the back side of the breathable sheet material, sufficient airtightness within the mold cannot be obtained, making it extremely difficult to mold the skin material. Ta.

The present invention was proposed in view of the above circumstances, and it facilitates the molding of a skin material including a breathable sheet-like material such as cloth, and simultaneously molds the skin material and a foamed synthetic resin layer. The purpose of this invention is to provide a new molding method that can be realized extremely easily.

This invention provides a skin material in which a plastic sheet is arranged on the back side of an air-permeable sheet-like article, and a mold and a plastic sheet are placed on the mold side so that the air-permeable sheet-like article is placed on the side of the mold and the plastic sheet is placed on the lid side. The plastic sheet is held between lid molds, air pressure is applied to the plastic sheet from the lid mold side, and vacuum suction is applied from the mold side to hold the skin material integrally in a predetermined mold shape, and then the plastic sheet is held in a predetermined mold shape. The present invention relates to a method of molding a foam molded article having a skin, characterized in that a foamed synthetic resin layer is molded integrally with the skin material by injecting a foamable resin material from the side.

Examples will be described below with reference to the accompanying drawings.

Fig. 1 of the accompanying drawings is a partially cutaway sectional view of a seat cushion for a chair showing an example of a product obtained by the present invention, and Fig. 2 and subsequent drawings sequentially show examples of the method of the present invention for molding the seat cushion. Figure 2 is a cross-sectional view of the mold showing the state in which air pressure is applied to the plastic sheet of the skin material from the lid mold side, and Figure 3 is a cross-sectional view of the mold showing the condition in which air pressure is applied to the plastic sheet of the skin material from the lid mold side. FIG. 4 is a cross-sectional view showing a state in which a foamed synthetic resin layer is molded integrally with a skin material by injecting a foamable resin material. be.

The seat cushion 10 of the chair shown in FIG. ) is formed integrally with a foamed synthetic resin layer 14 such as polyurethane resin. In the figure, reference numeral 15 is a back plate, and 16 is a decorative board forming the back of the chair.

Next, regarding the figures below in Figure 2, this seat cushion 1
The method of the present invention will be explained using 0 as an example.

FIG. 2 shows an apparatus for integrally molding the skin material 11 and the foamed synthetic resin layer 14 of the seat cushion IO, and shows a mold 20 having a cavity 21 having a predetermined skin shape and a foamed synthetic resin layer corresponding to the mold 20. It is composed of a lid mold 30 necessary for molding the resin layer 14.

In this invention, in particular, the mold 20 is provided with appropriate vacuum suction holes 25, 25, etc. connected to a vacuum device (not shown) for molding the skin material 1, and a lid is provided. The mold 30 is provided with an air hole 35 connected to a pressure device (not shown) for applying air pressure to the plastic sheet 13 as the skin material. Further, the lid mold 30 requires a hole for injecting the foamable resin material into the mold, but this can also be used as the air hole 35 described above as in the embodiment, and this is preferable.

The skin material 11 is made of natural or synthetic fiber and has a thickness of 2 to 3
It consists of a breathable sheet-like material 12 made of a layered cloth and a plastic sheet 13 disposed on the back side of the breathable sheet-like material, for example, a vinyl chloride sheet with a thickness of about 151 L. These breathable sheet-like material 12 and plastic sheet 13 may or may not be adhered to each other.

For the upper skin material 11, a breathable sheet-like material 12 is placed in a mold 20.
On the other hand, the plastic sheet 13 is held between the edge joints 22 and 32 of the mold and the lid mold so as to face the lid mold 30.

Then, air is introduced into the mold through the holes 35 of the lid mold 30, and air pressure is applied to the plastic sheet 13 on the back surface of the skin material 11. When air pressure is applied to the plastic sheet 13, the skin material 1 deforms toward the mold side as shown in FIG. 13 strongly presses the air-permeable sheet material 12 to maintain airtightness of the area. The air pressure at this time is
It is approximately 1 to 2 kg/cm depending on the material and thickness.

In this state, when the air in the cavity 21 is sucked and removed through the vacuum suction holes 25, 25, etc. of the mold 20, the skin material 11 is airtightly held, so that the air in the cavity 21 is removed as shown in FIG. 21, and is integrally maintained in a predetermined mold shape and molded.

If heat is required when forming this skin material 11,
The air introduced into the mold through the hole 35 of the lid wall 30 may be heated to generate hot air.

After the skin material 11 is molded into a predetermined mold shape, the shape of the skin material is maintained as it is, and a foamable resin material 41 such as polyurethane resin is injected from the lid wall 30 side.
6. When injecting the foamable resin material 41, the foamed synthetic resin layer 14 is formed integrally with the lid wall 30.
It is preferable to insert the injector 40 through the air hole 35 without opening it.

At this time, in order to maintain the molded shape of the skin material 11, it is desirable to keep air drawn from the vacuum suction hole 25, because loose, thick cloth, etc. have a large restoring force.

A foamable resin raw material 41 such as polyurethane resin is injected and then foamed and molded into a predetermined shape.
Glue together to form the product shape. In addition, the skin material 11
The plastic sheet 13 may melt during foam molding.

As explained above, according to the present invention, molding of the skin material including the breathable sheet material, which was conventionally considered difficult to integrally mold with the foamed synthetic resin layer from the viewpoint of airtightness, can be performed on the lid mold side. This can be done extremely easily and reliably by applying air pressure to a plastic sheet placed on the back side of a more breathable sheet material and vacuum suction from the mold side. It has now become possible to dramatically improve the packaging efficiency of foam molded products.

In particular, this invention is not only advantageous in terms of equipment and process since it is possible to simply introduce air without the need for special equipment or jigs, but also allows the mold to remove undercut portions. It has the advantage that the skin material can be easily molded even if it contains it. Further, as described in the embodiments, the practical advantages of this invention are enormous, such as the fact that one skin material can be easily molded by using hot air as air.

[Brief explanation of drawings]

Fig. 1 is a partially cutaway sectional view of a seat cushion for a chair showing an example of a product obtained by the present invention, and Fig. 2 and the following figures sequentially show examples of the method of the present invention for molding the seat cushion. Figure 2 is a cross-sectional view of the mold showing the state in which air pressure is applied to the plastic sheet of the skin material from the M mold side, and Figure 3 is the same (the skin material is removed by vacuum suction from the mold side). FIG. 84 is a cross-sectional view showing a state in which the foamed synthetic resin layer is molded integrally with the skin material by injecting the foamable resin material. 11...Skin material, 12...Breathable sheet material, 13
... Plastic sheet, 14 ... Foamed synthetic resin layer, 20 ... Molding mold, 25 ... Vacuum suction hole, 3o.
...Lid wall, 35...hole, 4o...injection machine, 41...
・Foamable resin material. 2!1 Figure 2

Claims (1)

[Claims] A skin material made of a plastic sheet arranged on the back side of a breathable sheet-like material, and a skin material made of a plastic sheet placed on the back side of the breathable sheet-like material, and the above-mentioned breathable sheet-like material placed on the mold side.
A plastic sheet is held between a mold and a lid mold so that it faces the lid mold side, and air pressure is applied to the plastic sheet from the lid mold side while vacuum suction is applied from the mold side to integrate the skin material. molding into a predetermined mold shape, and then injecting a foamable resin material from the lid mold side to mold a foamed synthetic resin layer integrally with the skin material. Method.