JPS6227989A - Production of cushion body - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to a method for manufacturing a cushion body in which a pad is covered with a skin, such as a headrest or a seat body of an automobile seat.

<Conventional technology> Conventionally, for example, the manufacturing of headrests for automobile seats was
Generally, a pad formed into a predetermined shape is coated with a skin created in a separate process, and this method has the problem of requiring a large number of processes and poor productivity.

As a method of reducing the number of steps, a method of integrally molding the skin and the pad is known. This method involves molding the skin in a vacuum mold to match the shape of the pad, then
A foaming solution such as polyurethane resin is injected into the epidermis and foamed, and the epidermis and pad are integrally molded.

<Problems to be Solved by the Invention> However, in order to maintain comfort when sitting or using the skin, the skin is generally made of a breathable skin. When the foaming stock solution is foamed, the foaming stock solution leaks out from between the grains and textures of the epidermis and foams, and the periphery of the epidermis is covered with the leached and foamed resin. For this reason, many defective cushion bodies are generated. Furthermore, since a bag-like shape like a headrest is made from a single piece of skin, it is necessary to use a special material with high extensibility for the skin, which limits the degree of freedom in material selection. Furthermore, when the pad is foam-molded, the strength of the skin decreases if the skin is stretched excessively, so there are design restrictions on the shape of the cushion body.

Means for Solving the Problems> The present invention was made in consideration of the above circumstances, and provides a method for manufacturing a cushion body in which the foaming solution does not leak out to the outside and the flit tension of the skin does not become excessive. be.

Therefore, in the present invention, after inserting a breathable skin and a non-breathable film into a vacuum mold with the film inside, the pressure of the vacuum mold is reduced to bring the skin and film into close contact with the inner wall of the mold. It is characterized by injecting a foaming solution into the film and foaming it to form a pad.

<Function> The non-breathable film is located inside the epidermis and prevents the foaming solution from seeping out to the outside of the epidermis.

<Example> An example in which the present invention is applied to a headrest of an automobile seat will be explained in detail in accordance with the attached opening book, page 2, and process order. FIG. 1 is a perspective view of a skin material 1. FIG. This skin material 1 is made of an air-permeable material, and a tongue piece 1a is formed in a part thereof, and the other part except for this tongue piece 1a is formed into a bag shape that matches the shape of the pad.

This can be made into a bag shape by sewing the ends of each part with sewing thread, or by high frequency welding or the like. FIG. 2 shows an illegal film 2 inserted into the bag-shaped skin 1, and this film 2 is also formed into a bag shape with only the tongue piece 2a open. As such a breathable film 2, for example, a resin film such as polyurethane or polyvinyl chloride is used. In this way, the epidermis 1. The film 2 is inserted into a vacuum mold 5 shown in FIG. The vacuum forming mold 5 consists of a cavity 5a which is a hollow part in the shape of a radrest, a suction hole 5b opened in the cavity 5a, an injection port 5d for the foaming stock solution, and a pressure reduction path 5c connected to a pressure reduction means. The skin 1 and the film 2 are inserted into the cavity 5a of the vacuum forming mold 5. First, the skin 1 is inserted, and then the film 2 is inserted inside the skin 1. In the case of B, the tongue piece 1a of the epidermis 1 and the tongue piece 2a of the film 2
is pulled out from the vacuum mold 5 and fixed between the fixing frames 4 attached to both sides of the injection port 5d. In this way, the skin 1 inserted into the vacuum molding mold is molded into a bag shape to match the shape of the pad to be molded, thereby making it possible to suppress the elongation of the skin to 10 to 20%. If it is necessary to adhere the skin 1 and the film 2, an adhesive may be applied to either or both of the inner surface of the skin 1 and the outer surface of the film 2 in advance. This adhesive can be either a pressure-sensitive adhesive or a heat-sensitive adhesive.

Next, as shown in FIG. 4, the air inside the vacuum forming mold 5 is sucked from the vacuum path 5C of the vacuum forming mold 5, and this suction force brings the skin 1 and the film 2 into close contact with the inner wall of the cavity 5a. Inject the foaming stock solution 6-, such as polyurethane, into the cavity 5a from the nozzle 9 facing the injection port 5d. Then, as shown in FIG. 5, while maintaining the reduced pressure state, that is, while keeping the skin 1 and film 2 in close contact with the inner wall of the cavity 5a, the head 1/steer is inserted from the injection port 5d, and the cap 10 is After closing the injection port 5d, the foaming stock solution is foamed to form a pad. During this molding, since the inner surface of the skin 17 is covered with a non-breathable film, the foaming stock solution will not leak out of the skin. In addition, when the adhesive is a heat-sensitive adhesive, the skin 1 and the film 2 can be bonded together by injecting the foaming solution and then heating the inside of the vacuum mold to bond the skin and the film at the same time as pad forming. Well, the cushion body (
After the pad) is formed, it may be removed from the vacuum mold and bonded by heat pressing.

Finally, the tongues 1a and la of the epidermis 1 and the tongues 2a and 2a of the film 2 are joined together by appropriate means such as suturing.

FIGS. 6 and 7 are perspective views of the headrest 1 formed as described above, turned sideways. In the case of a cushion shape as shown in FIG. 6, the skin 1 and the film 6 are bonded together. Although it is not necessary to do so, in the case of a cushion shape as shown in FIG. 7, it is necessary to bond the skin 1 and the film 2. FIG. 8(a) is a sectional view taken along the line ■-■ in FIG. 7. In FIG. 8, 11 is a pad formed by foaming a foaming solution, and as shown in the enlarged view (b), a skin 1 and a film 2 are bonded together via an adhesive 12.

<Effects of the Invention> As described above, according to the present invention, since the epidermis and the pad are integrally molded, the process of covering the epidermis onto the pad is reduced, and the non-breathable film is inserted into the inner surface of the epidermis. There is no leakage of the foaming stock solution to the outside of the epidermis, and a normal skin material that does not cause excessive stretching of the epidermis can be used, which has the effect of expanding the room for material selection and the degree of freedom in design.

[Brief explanation of the drawing]

Figures 1 and 2 are perspective views of an example of the skin and film used in the present invention, Figures 3 to 5 are cross-sectional views of the manufacturing process, and Figures 6 and 7 are of the head l/st. FIG. 8(a) is a sectional view taken along the line ■-■ in FIG. 7, and FIG. 8(b) is an enlarged view of the main part of (a). 1. Epidermis, 2. Film, 5. Vacuum mold, 11. Pad.

Claims (2)

[Claims] (1) A breathable skin with a non-breathable film inserted inside is inserted into a vacuum molding mold, the pressure inside the mold is reduced to vacuum form the skin, and a foaming stock solution is injected into the mold to form a pad. Characteristic method for manufacturing the cushion body. (2) The method for manufacturing a cushion body according to claim (1), wherein an adhesive is applied to either the non-breathable skin film or the skin.