JPS63188008A - Manufacture of monolithic foam molded seat body - Google Patents

Abstract

PURPOSE:To contrive a reduction in man hours and improvement in reliability by fitting a skin material to a foam mold simply and accurately, by a method wherein a mold part coincides with a part obtained by joining a skin material to a skin end fitting member is formed on the fringe of the upper part of the inner mold part of a bottom force, the skin material is stuck to the inside of the bottom force and the skin material and urethane mold are foamed unitarily by casting foamed raw materials. CONSTITUTION:O-P-Q parts of a skin material 1 fitted to a fitting member 3 of a terminal of the skin material is bent and fitted after a bottom force 6. The terminal part of the skin material 1 is positioned between O-P parts of the bottom force 6, and a, top force 8 is inserted into the skin material by descending the top force 8, In the case where the fitting member 3 of the terminal of the skin material has elasticity, the same is fitted by pressing the same against the bottom force 6. Then urethane foam raw materials are either foamed by casting the same through raw material casting port 8a or foamed by the top force 8 heaving no raw material casting port 8a by casting the urethane raw materials into the bottom force. In the case where a casting and foaming method is of neither high pressure nor a high speed, a heat-meltable film is put on the skin or a wadding on which the urethane raw materials are cast and foaming is performed by inhibiting impregnation. Then the heat-meltable film is melted and the urethane and the skin or the wadding are stuck together.

Description

[Detailed Description of the Invention] Industrial Field of Application The present invention provides a technology for easily and accurately attaching the end of the skin to the foam mold when molding a seat body, and for sharpening the decoration of the unevenness of the skin. used in the field.

Conventional technology When integrally foaming the skin and the urethane mold that is the filler, conventionally the end of the skin is attached to a predetermined position on the lower mold, and the skin has an uneven shape for decoration (e.g. grooves, etc.). Button shapes, marks, etc.) are formed during urethane foaming.

Problems to be Solved by the Invention It is difficult to accurately attach the above-mentioned skin end to a predetermined position on the lower mold, requiring a large amount of skill and man-hours, resulting in many defective products, and it is difficult to properly attach the skin end to the lower mold. For molding, using only the foaming pressure of urethane, the pressure was weak and it was difficult to pressurize the skin and mold it into an accurate shape.

Means for Solving the Problems The present invention takes the following measures in order to solve the above-mentioned problems. That is, the skin material is placed along the engraved shape into a lower mold of urethane mold foam with the surface shape of the seat body engraved on the inside, the urethane mold raw material is injected, and the skin and urethane are integrally foam-molded. In the manufacturing method of the seat body, a mold part is formed on the upper periphery of the inner mold part of the lower mold to match the part where the skin material is joined to the skin end attachment member,
The skin material is attached to the inside of the lower mold, and a foaming raw material is injected to integrally foam the skin material and the urethane mold.

According to the above-mentioned means, the above-mentioned disadvantages of the prior art are eliminated, the attachment of the skin material to the foam mold becomes simple and accurate, the cost is reduced, and the drawbacks of the prior art are greatly improved.

Embodiments Next, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

The cross sections of typical seat bodies are shown in Figures 1a, 1b and 2a.
The finished product of the seat body will be described with reference to FIGS. 2b, 2b, and 2c. In the illustration, the seat is upside down, and the seat is seated on the bottom.

The skin material 1 has the shape of a seat body as shown in the figure. The skin material 1 is adhered to the urethane mold 2 when the urethane is foamed. A peripheral end portion of the skin material l is connected to a skin material end attachment member 3. A skin material attachment part 4a is provided in a part of the frame 4, and is assembled to the frame 4 by inserting it between the skin materials I connected to the skin end attachment member 3.

FIG. 1b shows a skin material end attachment member 3A having a hook-shaped cross section and having the same purpose as the skin material end attachment member 3 of FIG. 1a.

FIG. 2a shows a cross section of the rear side of the seat body. A skin material 1 and a skin material end attachment member 3 are inserted and assembled between the lower frame line 5 and the urethane mold 2 instead of the skin material attachment portion 4a of FIG. 1a. The lower frame line 5 may have a plate-like shape. The middle part IA and the gusset part IB may be made of different skin materials, and are joined at the skin joining part 1a. Figures 2b and 2c also show cross sections on the rear side.

Skin material 1. IA, 113 may be woven fabric, knitted fabric, non-woven fabric, other cloth, vinyl leather, etc., and a material with stretchability is used depending on the molding shape. Although not shown in the drawings, the skin material 1 may have wadding bonded with an adhesive or a heat-sealed laminate bonded thereto.

Next, the manufacturing method according to the present invention will be explained.

0- of the skin material 1 attached to the skin material attachment part 4a in FIG. 1a.
The P-Q section is bent as shown in 0-P-Q in FIG. 3 and attached along the lower die 6. The end portion of the skin material 1 is positioned between the OP portions of the lower mold 6, and the upper mold 8 is lowered and inserted. If the skin material end attachment member 3 has elasticity, it can be attached by pressing it against the lower mold 6.

Next, the urethane foam raw material is injected from the raw material injection port 8a and foamed, or the urethane raw material is injected into the lower mold using the upper mold without the raw material injection port 8a and foamed. Further, the injection foaming method includes a high-pressure, high-speed, low-temperature foaming HR mold or a low-pressure, high-temperature HOT mold, and either method can be applied to the present invention. If high pressure and high speed are not used, a heat meltable film is placed on the skin or wadding (not shown), and the urethane raw material is injected onto it to prevent impregnation and after foaming, heat meltable soy 3-1 and lume are added. Melt and adhere urethane and skin to Waainogu.

When removed from the lower mold 6 after completion, the shape of the skin material 1 and the urethane mold 2 are overhung (wider at the bottom in the figure), but since the skin material 1 and the urethane mold 2 are soft and can be deformed, the shape of the skin material 1 and the urethane mold 2 are It can be taken out from. After taking it out, it has the shape of 0-P-Q in FIG. 1a. In order to sharply form the grooves 1b (Figures 1a and 3), one piece of skin material 1 is pressed with the convex part 6a of the lower mold 6 and the concave part of the upper mold (not shown) before foaming to form the skin 1. Good.

A taper is attached to the inside of the P-Q section in FIG. 3 to improve the airtightness between the upper mold 8 and the lower mold 6. This is common to all figures.

FIG. 4 shows the skin material end mounting member 3 of FIG.
-P is attached to the lower mold 6.

The method for attaching the mounting member 3 to the lower frame line 5 in FIG. 2a is also shown in FIG.
It can be manufactured using the same method as shown in Figure 4.

As described above, the skin material end attachment member 3 shown in each figure may be joined to the entire circumference of the end of the skin material 1, or there may be a portion that is not joined depending on the shape of the seat (not shown).

FIG. 5 shows that the lower mold 6 shown in FIG. 3 is provided with a lower mold lower frame mounting portion 9a of the skin attachment plate 9A to facilitate attachment to the lower mold 6.

FIG. 6 shows the case of FIG. 2C in which the skin material end attachment member 3 of FIG. 2a is omitted. This is made by welding two lower frame lines 5 to the lower frame joining line 5A, and is attached to the lower mold 6 (generally, the part protruding from the lower mold 6 is used to fix the rear seat to the car body. ).

The purpose of the embodiment shown in FIG. 6 is to impregnate the urethane mold 2 into the skin material IB and fix it in contact with the lower frame line 5 and the lower frame joint line 5A.
Although not shown, elastic bodies such as springs, seat constituent members such as the lower border line 5 and the frame 4 are also foamed together, so that the sewing and assembly work is completed at the same time by foaming them together.

FIG. 7 shows the case of FIG. 2b and has the same purpose as FIG. 6 above. An arc-shaped R portion is provided on the upper die 8, as shown by the dotted line.
When the skin material IB hits the R part and the upper mold 8 descends, the skin material IB
B gets caught up in the R section, resulting in the state shown in FIG. The skin material IB is impregnated into contact with the urethane mold 2 and fixed.

In FIG. 8, a button shape is formed in advance on the skin material 1 and wadding 12 outside the lower mold 6 using high frequency, etc., and the convex portion 6b of the lower mold 6 is formed.
It is attached to the button-shaped support part of the button and foamed integrally.

Similarly to FIG. 8, in FIG. 9, a groove is formed outside the lower mold 6 (the groove 1b in FIG. 3 is formed by molding the skin with a foam mold).

Effects of the Invention According to the present invention, the method of attaching the ends of the skin to the foam mold, which was a drawback of the conventional method, can be solved by the method described in the embodiments of FIGS. 3, 4, 5, 6, and 7. As a result, it can be easily and accurately attached during foam molding, and the drawbacks of the conventional method are greatly improved.

In addition, the third method for sharpening the unevenness of the decoration on the epidermis is
Convex portion 6a in the figure, convex portion 6b in FIGS. 8 and 9.

This was achieved by 6c etc.

[Brief explanation of the drawing]

Fig. 1a is a sectional view of a typical seat body, Fig. 1b is a partial sectional view showing the upholstery end attachment member, Fig. 2a is a sectional view of the rear side of the seat body, and Fig. 2b is a sectional view of the upholstery end. Rear side - immediate sectional view, Figure 2c is a partial sectional view showing the joining line and lower frame line on the rear side, and Figure 3 is a tapered part on the inside to improve airtightness between the upper and lower molds. Figure 4 is a cross-sectional view of the skin material end attachment member attached to the lower mold on the side, and Figure 5 is a lower frame attachment part provided to facilitate attachment to the lower mold. 6 is a sectional view of an example in which the skin end attachment member is omitted, FIG. 7 is a sectional view of an example in which the skin end attachment member is omitted on the rear side, and FIG. 8 is a sectional view of an example in which the skin end attachment member is omitted on the rear side. FIG. 9 is a partial cross-sectional view of an example of molding outside, attaching it to the button-shaped support part of the lower mold, and performing integral foaming, and FIG. 9 is the same as FIG. 8.
FIG. 7 is a partial cross-sectional view of an example in which the groove portion is molded outside the lower mold. 1, LA, IB...Skin material, 1a...Skin connection part,
1b...Groove, 2...Urethane mold, 3...Skin material end attachment member, 4...Frame, 4a...Skin material attachment part, 5...Bottom frame line, 5A...Bottom frame joining line, 6...・Lower mold,
6a, 6b, 6c...Protrusion, 8...Upper mold, 9...
Lower mold mounting part, 9A...Skin mounting plate, 12, 2nd (L figure
Figure 2b Figure 6 Figure 7

Claims (1)

[Claims] 1. A skin material is placed along the engraved shape in a urethane foam lower mold with the surface shape of the seat body engraved on the inside, a urethane mold raw material is injected, and the skin and urethane are bonded together. A method of manufacturing a seat body by integrally foaming molding, in which a mold part that matches the part where the skin material is joined to the skin end attachment member is formed on the upper periphery of the inner mold part of the lower mold, and the skin material is attached to the inside of the lower mold. A method for manufacturing an integrally foamed seat body in which the skin material and urethane mold are integrally foamed by bonding the skin material to the urethane mold and injecting foaming raw materials. 2. A method for manufacturing an integrally foamed seat body according to claim 1, in which the edges of the gusset portions of the skin material are integrally foamed and bonded to the urethane mold without using a skin material end attachment member. 3. The method for producing an integrally foamed seat body according to claim 1, wherein the seat constituent members such as the skin material and the frame are integrally foamed at the same time as the urethane molding, and the sewing and assembly work is completed at the same time as the urethane molding. 4. The method for manufacturing an integrally foamed seat body according to claim 1, in which uneven portions are previously formed on the skin and wadding outside the foaming lower mold, and then the molded product is inserted into the convex portions of the lower mold and integrally foamed.