WO1991016186A1

WO1991016186A1 - Instrument for pouring foamable material and method of producing foam having integrated skin

Info

Publication number: WO1991016186A1
Application number: PCT/JP1991/000496
Authority: WO
Inventors: Joh Kashiwabara; Yasuo Tanaka
Original assignee: Namba Press Works Co., Ltd.
Priority date: 1990-04-19
Filing date: 1991-04-16
Publication date: 1991-10-31
Also published as: JPH0642816Y2; JPH042608U; AU7661491A

Abstract

An instrument for directly pouring foamable material into a previously sewn skin (30), which is provided with a funnel (1) wherein at least one side discharge port (7) in additon to a straight-forward discharge port (6) is provided and the flow of the material is divided in order to prevent the inner surface of the skin from being directly locally impacted. To further facilitate the dividing and dispersing of the material, this funnel (1) may be combined with a dispersing plate (10) having a scattering portion (15) relating to the side discharge port (7) and a buffle plate portion (16) relating to the straight-forward discharge port (6), or, further, the funnel may be combined with an opening blocker (20) for blocking an aperture (32) in the skin for use as an assembly for pouring.

Description

Description Apparatus for injecting foamable material and method for producing epidermis-integrated foam product using the same

The present invention relates to a device for injecting a foamable material used for producing a skin-integrated foamed product, for example, a headrest of an automobile seat, and a method for producing a foamed product using the same.

You

As a technique for making foam molded products such as headrests and armrests for car seats or other seats, the skin is preliminarily sewn to the outer contour of the final product. There is a known method of directly injecting the undiluted solution into 中. In this case, if the epidermis is lined with, for example, a non-breathable plastic film, the injected foaming solution does not leak out of the epidermis, but instead foaming reaction The inconvenience is that the gas generated from the gas cannot escape to the outside. Therefore, it is desirable to make the epidermis breathable in the method of directly injecting the effervescent stock solution into the epidermis made from 鏠; however, this time, directly into the permeable epidermis made from 鏠The stock solution injected into the injection nozzle hits the back side of the epidermis in front of the nozzle at high speed from the tip of the injection nozzle, foams out there, penetrates and leaches into the epidermis, and hardens, resulting in a localized hard silicon There is a problem of forming so-called hard spots. Disclosure of the invention

In view of the above background, the present invention distributes and disperses the foamable raw material liquid to be directly injected into eight of the previously sewn epidermis into the sewn epidermis without direct local injection to the inner surface of the epidermis. It is intended to provide a new injection device.

It is another object of the present invention to provide a method for using a foam-integral foam product such as a headrest or an armrest by using such a novel foamable material injection device. .

In order to achieve the above-mentioned object, the present invention provides a device for injecting a novel foamable material according to the present invention into a skin prepared in advance into a desired three-dimensional shape of a final product, for example, a headrest. Then, a foaming material of high pressure and high speed is injected, and the foaming material is shunted and decelerated in the epidermis to produce a foamed product integrally bonded with the epidermis without leaching from the epidermis.

The injection device of the present invention basically includes a straight discharge port for discharging a foamable raw material to be injected in a straight-moving direction into a discharge cylinder connected to a conical injection port, and a discharge port in front of the straight discharge port. It consists of a funnel with a lateral discharge port for diverting the flow of the injection material in the horizontal direction. With this configuration, the foamable material containing the required amount of air and supplied to the injection device at a high pressure does not pass all the way through the straight discharge port at a high speed, and a part of the foamable material is lateral. The fluid is diverted to the discharge port and dispersed into the inner space of the skin, and the discharge flow from the straight discharge port is decelerated and spreads to the inner space of the skin, so that the inner surface of the skin in front of the straight discharge port is not hit directly. Become.

In order to further enhance such a diverting effect, In a suitable mode, the funnel provided with the side discharge port and the straight discharge port as described above is further provided with a flyer part for dispersing the branch flow from the side discharge port in both directions at a right angle, A sub-assembly for injecting foamable material, which is used in combination with a dispersing plate provided with a baffle plate for diverting the straight discharge flow from the straight discharge outlet to the left, right, up and down, etc. . As a result, the distribution of the injected material in the 鏠 -made skin is further homogenized, and a high-quality foam molded product in which each part is foam-hardened evenly is obtained.

If the foamed product requires a skeletal part (stain) in the foam, such as a headrest, the skeletal part can be used to construct the dispersion plate of the present invention. And can be.

If an opening or a slot for inserting the skeletal component as described above is formed in the pre-sewn skin, the opening or the slot is closed to prevent leakage of the injection material and to prevent the product from being leaked. An opening closing device that closes the opening or slot is required to make the appearance beautiful, but such an opening closing device is required to be connected to the straight discharge port and the side discharge port as described above. If the injection assembly is combined with an injection subassembly consisting of a funnel provided with a dispersing plate and a dispersion plate, and this assembly is used to produce a foamed product, There is an advantage that the installation of the device and the setting of the entire epidermis with the device mounted on the molding mold can be performed extremely easily.

Thus, according to the present invention, in a method for directly injecting a foamable material into an epidermis sewn into a shape corresponding to the contour of a final product in advance, a novel injection device is inserted into the epidermis. And high-speed materials A method of manufacturing a skin-integrated foamed product is realized, in which the material stream is diverted in the epidermis, decelerated, and uniformly dispersed and foamed without directly colliding with the inner surface of the epidermis.

In the basic aspect of the method of the present invention, the injection device used is such that a straight-moving discharge port is opened at a tip of a discharge cylinder portion connected to a conically expanding filling port, and the straight-moving discharge port is located before the straight-moving discharge port. It is composed of a funnel with a side discharge port formed in it. In order to further enhance the diverting, decelerating and dispersing effects, an injection for a combination of a flyer part close to the side discharge port and a dispersion plate having a baffle plate provided in front of the straight discharge port is used. The subassembly is used as an injection device.

If the opening formed in the skin pre-sewn to the separately prepared final product shape is to be closed using an opening closure that is integrated with the skin, the injection subassembly and this opening closure are connected. The input assembly may be used as an injection device, and the straight discharge port and the side discharge port, as well as the flyer and baffle plate, are inserted from the opening into the sewn skin, and the opening closing tool is used. The opening is closed, the inlet of the funnel is connected to a supply source of the foamable material, and a predetermined amount of the foamable material is injected into a leather epidermis and dispersed and foamed. A method of manufacturing a skin-integrated foamed product by extracting the material is realized.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a side view of a funnel which is a basic element of the injection device according to the present invention.

Fig. 2 shows the injection funnel and dispersion plate of the present invention. FIG. 4 is a partially cutaway side view (corresponding to line II-III in FIG. 3) of the injection assembly in which the injection subassembly thus formed is combined with an opening closing device.

FIG. 3 is a front view showing the injection assembly including the funnel, the dispersing plate, and the opening closing device shown in FIG. 2 inserted into a pre-sewn skin indicated by imaginary lines.

FIG. 4 is a bottom view showing an opening on the bottom surface of the pre-sewn epidermis shown by a chain line in FIG.

FIG. 5 is an enlarged cross-sectional view corresponding to the line VV of the opening closure shown in FIG.

FIG. 6 is a view showing a step of injecting the foamable material using the injection assembly of the present invention. FIG.

Best form for carrying out the invention

An embodiment of the injection device of the present invention will be described with reference to the drawings, together with a method for producing an epidermis-integrated foam product to be implemented thereby. FIG. 1 shows a funnel 1 which is a basic element of the injection device of the present invention. This funnel 1 is preferably molded entirely of plastic, and gradually narrows from the open end 2a to the front end 2b of the conical injection port 2 and becomes cylindrical at the front end 2b. Is continuous. The cylindrical portion 3 is continuous with the discharge cylindrical portion 5 via the taper portion 4, and the distal end of the discharge cylindrical portion 5 opens as a straight discharge port 6. A side discharge port 7 is formed in the wall of the cylindrical portion 5 slightly before the straight discharge port 6.

The inlet 2 is connected to a pipe or hose (not shown) that is in contact with the supply source (machine head) of the foaming raw material liquid. 璟 -shaped protrusions 2 c are formed inside. The foamable raw material liquid is preferably a high-speed reaction type urethane, and particularly in the case of the funnel 1 of the present invention, a raw material liquid containing a required amount of air is preferable. The discharge cylinder portion 5 is a portion to be inserted into a sewing skin 30 as shown in FIG. 3 or FIG. 5, and the cylinder portion 3 is formed together with the skin by a molding mold (see M in FIG. 6 described later). This is the part that is held. When using the funnel 1 alone as an injection device, the discharge cylinder part 5 can be inserted into the epidermis by drilling a small hole in a suitable place in the preformed and closed epidermis. Good. After injecting the foamable material, if the foaming is properly advanced and the funnel 1 is pulled out, the expanding foam will close the small hexagons, so there is no risk of material leakage and the holes will not be noticeable .

Conventionally, a nozzle without a side discharge port 7 and only a front discharge port corresponding to a straight discharge port 6 has been used, but with such a nozzle, a foamable raw material liquid to be discharged is used. However, it hit the inner skin surface in front of the nozzle, and there was a problem that the above-mentioned hard spot was formed. According to the present invention, since at least one side discharge port 7 is provided on the side wall of the discharge cylinder portion 5, it is necessary to discharge at high pressure to the machine head as described above. The foaming stock solution containing a certain amount of air is first diverted in the lateral direction in the advancing direction at the side discharge port 7 and discharged, whereby the discharge flow from the straight discharge port 6 is decelerated, and the front inner skin surface It was acknowledged that direct hits would dramatically decrease. As a result, even if the skin is air-permeable (permeable), there is an effect that hard spots are formed and defects such as poor dispersion and non-uniformity of the foaming material are largely eliminated. 1-FIGS. 2 and 3 show a preferred embodiment of the injection device according to the present invention which is based on the same principle of the above-described branch flow deceleration. This preferred embodiment is constructed by combining the funnel 1 of the present invention shown in FIG. 1 with a separately prepared dispersion plate 10. The illustrated dispersion plate 10 is formed by appropriately combining the rain side 緣 12 of a sheet metal plate with a pair of stainless steel rods 11, and the sheet metal plate has projections 13 formed at several places. However, the convex portion may have another shape, or may be a smooth dispersion plate 10 from which the convex portion is omitted.

In FIGS. 2 and 3, the dispersion plate 10 has a holding portion 14 near the lower end, and the discharge cylinder 5 of the funnel 1 is fixed to the holding portion by passing through the holding portion as shown in FIG. The funnel 1 is inserted into the holding portion 14 with its side discharge port 7 facing the dispersion plate. The area of the dispersion plate 10 close to the side discharge port 7 is called a flyer part 15, and the foamable raw material liquid discharged from the side discharge-outlet 7 is divided into left and right sides as shown by arrows L in FIG. It acts as a side stream.

A baffle plate portion 16 is formed at a position forward (upper end in FIGS. 2 and 3) of the funnel straight discharge port 6 of the dispersion plate 10. In the example shown in the figure, the baffle plate portion 16 is drawn as being curved in an arc shape, which is preferable, but at least the discharge flow from the straight discharge port 6 does not proceed straight. The baffle plate portion 16 may be formed in any other suitable shape that can be partially turned.

Baffle portion, the earthenware pots by apparent in Figure 3, also has a smaller baffle plate 16 I 16 ₂ which are arranged at a slight spacing on the left and right of the center of the main wicked Maban 16 . These baffles are 16 ぃ 16 ₂ etc. One S-baffle 16 is for further dispersing the flow of the foamable material whose direction has been changed by the baffle plate 16 so as to achieve a more uniform dispersion.

The funnel 1 combined with the dispersing plate 10 is set into a skin made in advance to the contour of the final product as shown by the imaginary line 30 in FIG. The sewing skin 30 shown in FIG. 3 is for a headrest, and the dispersion plate 10 is left in the skin 30 as a skeletal member. When the conventional injection nozzle is placed in the position occupied by the funnel 1 of the present invention in FIG. 3 and the foamable material is injected, the discharge flow from the nozzle tip hits the top 30T of the skin directly, If the material was permeable (breathable), it penetrated there and hardened to form an inconvenient hard spot. However, according to the present invention, as described above, the foamable material (for example, high-speed reaction urethane) injected into the funnel 1 at a high pressure is discharged to the side discharge port 7 and the discharge flow decelerated is reduced. In addition to exiting from the straight discharge port 6, the branch flow from the side discharge port 7 is immediately scattered to the left and right by the flyer portion 15 of the dispersion plate 10, and then spreads out. Figure 3 is a left small and also in part by the baffle plate portion 16 After straight on plates 10 Remind as arrow F t in FIG. 6 is as indicated by an arrow F _2, or the direction can vertically altered, smaller baffle plate 16 to be al; are distributed decelerated by ^ 16 _2, etc. conveniently diffuse into the epidermis. When the foamable material that has passed over the baffle plate portion 16 comes into contact with the top 30T of the skin, the speed is already greatly reduced, and the foaming reaction has progressed. It does not locally penetrate deeply into the inner surface of the epidermis as in a shot. More specifically, when the final product is a headrest, it is preferable that the injection assembly of the present invention include a skin opening / closing device 20 as shown in FIGS. 2 and 3. is there. FIG. 4 shows a bottom view of the leather skin 30 closed by the opening closing device 20. The entire skin 30 is sewn in a box shape, as can be inferred from the location shown by the perforated line in FIG. 3, and an opening 32 is formed in the bottom surface 31 of the skin 30 in an elongated shape as shown in FIG. ing. At the center of the opening 32, an inlet 33 having a larger diameter than the discharge cylinder 5 of the injection funnel 1 is formed. At the rain end of the opening 32, a hole 34 having a diameter larger than that of the stay leg 11a which is an extension of the above-mentioned stay rod 11 is formed.

Such an opening 32 on the bottom surface of the epidermis is closed by the opening closing device 20 when the foamable material is injected. The opening closing device 20 is composed of two upper and lower plates 21 and 22 joined together with a gap 23 left therebetween, so that a rib 24 protruding between the upper and lower plates and a fan The two plates 21 and 22 are connected to each other by a discharge cylinder portion 5 and a pipe-like portion 27 (see FIGS. 2 and 3) penetrating the stay monopod 11a. Several portions of the rib 24 are lowered to leave a gap 25, and the portion of the plate 21 above this gap is perforated as a window 26, as can be seen from FIG. The gap 23 between the upper and lower plates 21 and 22 is where the edge of the opening 32 is received when the closure 20 is attached to the skin bottom 31, and the inner edge of the received edge is the fifth end. Look under window 26 in the figure.

According to the most preferred embodiment of the present invention, an opening closure device 20 as described above is injected in combination with a dispersion plate 10 and a funnel 1. Of the assembly. A cross-sectional view of the injection assembly is shown in FIG. 2, and a front view is shown in FIG. That is, the pipe-shaped portion 27 ₂ and揷通a stay leg 1 1 a combination of a dispersion plates 10 and the opening closure member 20 to then pipes shaped portion 27 (FIG. 2 central rain end closures 20 ) Is inserted through the discharge cylinder 5 of the funnel 1 of the present invention.

Such an injection assembly is inserted into the opening 32 on the bottom surface 31 of the skin from the tip side of the dispersion plate 10, that is, from the baffle plate 16, to the skin 30 shown by a chain line in FIG. When the predetermined position is reached, the edge of the opening 32 is inserted into the gap 23 of the opening closure 20. The combination of the sewing skin 30 and the injection assembly thus prepared is set in a molding die, preferably a resin molding M, as indicated by a chain line in FIG. Only the inlet 2 of funnel 1 protrudes outside. A foaming material containing a necessary amount of air in the urethane raw material A solution (vol-ol side) is discharged into the machine at a high pressure, as indicated by an arrow I, to the inlet 2. The discharge material is divided and discharged into the side discharge port 7 of the funnel 1 and the straight discharge port 6, and the flow from the side discharge port 7 is the flyer of the dispersion plate 10 as described above. The flow from the straight discharge port 6 is further dispersed right and left by the portion 15, and a part of the flow is diffused and expanded into the epidermis 30 over the baffle plate while being dispersed by the baffle plate 16. As described above, according to the production method of the present invention, the top 30 skins are not directly impacted by the high-speed discharge flow as in the conventional method.

After injecting is complete, remove funnel 1 and prepare for reuse One —

In both cases, mold M remains closed until foam hardening of the injected material is almost complete. In the process of foam hardening, the injected material is almost uniformly dispersed in the epidermis and penetrates shallowly into the breathable backing material such as the sponge layer on the inner skin surface 36 (Fig. 6), but does not leach up to the front surface 35. In addition, the foam and the skin are integrally bonded by curing at the shallow penetration portion. In the process of foam hardening as described above, the foam material reaching the vicinity of the upper plate 21 of the opening closure 20 penetrates into the skin at the edge of the opening 32 from the window 26 and hardens there. Since the opening is formed, the opening 32 is fixed so as not to come out of the closure 20, and the closure 20 itself is integrally connected to the epidermis, thus completing the production of a desired headrest.

Industrial applicability

As described above, according to the present invention, an injection device in which at least one lateral discharge outlet is provided in addition to the straight discharge outlet in the discharge cylinder portion of the funnel, which is a basic element of the injection device, is provided. , The foaming material such as high-speed reaction type urethane containing a certain amount of air and supplied at a high pressure is dispersed and expanded into a decelerated straight flow and side flow. This prevents high-speed flow from directly hitting only the inner surface of the epidermis, preventing the formation of hard spots and making it possible to manufacture foam moldings of excellent quality. effective.

This effect is achieved by combining the discharge cylinder part of the funnel with a dispersion plate having a flyer part facing the side discharge port and a baffle plate part located in front of the straight discharge port. Assembly, or even more One one

The use of the injection assembly in combination with the skin closure device has the effect of producing a high-quality skin-integrated foam product that is further enhanced and uniformly dispersed and foamed. is there.

According to the present invention, since there is no possibility of forming a hard spot even by a method of directly injecting the foamable material into the pre-sewn skin, the air-permeable skin is required to have a headrest and other similar products in advance. It is made into a three-dimensional shape, and foamable material is injected directly into it and foamed into a homogeneous and high-quality product.The skin-integrated foam product with low breathability and comfortable feel is relatively easy and economical. There is an advantage that it can be manufactured by a simple method.

Claims

Scope of the request: A discharge cylinder to be inserted into the skin previously formed in the shape corresponding to the contour of the final product is formed by connecting to the front end of the conically expanding injection port. Foaming composed of a funnel with a straight discharge outlet opened at the tip of the discharge cylinder and at least one side discharge port formed in the discharge cylinder before the straight discharge outlet For injecting conductive materials. A discharge cylinder to be inserted into the skin formed in advance in the shape corresponding to the contour of the final product is formed by connecting to the front end of the conical opening of the injection port. A straight discharge outlet is opened at the front side, and at least one side discharge port is formed in the discharge cylinder portion in front of the straight discharge outlet. And a baffle plate provided in front of the straight discharge port. A device for injecting a foamable material, comprising a subassembly for injection formed by combining with a dispersion plate. A discharge cylinder to be inserted into the skin formed in advance in the shape corresponding to the contour of the final product is formed by connecting to the front end of the conical opening of the injection port. A straight discharge outlet is opened at the front side, and at least one side discharge port is formed in the discharge cylinder portion in front of the straight discharge outlet. And a baffle plate provided in front of the straight discharge outlet, And a device for injecting a foamable material which is constituted by an injecting assembly which is combined with an opening closure which is fitted into an opening of a skin previously made in the contour of the final product. Prepare a pre-sewn skin in a three-dimensional shape corresponding to the contour of the final product,

The high-speed foaming material is injected into the skin while being decelerated and decelerated, and is uniformly dispersed with the skin without evenly colliding the material flow directly on the inner surface of the skin or exuding to the surface. A method for producing a foam-integrated skin product, comprising foaming into a foam. A small hole is drilled at an appropriate position on the skin, and a discharge cylinder portion of a funnel having a straight discharge port at the tip and at least one side discharge port in front of the small hole is inserted into the small hole. 5. The method according to claim 4, wherein the foamable material is injected by performing the injection. A straight discharge port is opened at the end of the discharge cylinder, and a funnel having at least one side discharge port formed in the discharge cylinder just before the straight discharge outlet is provided in the side discharge port. Combine with a dispersion plate having a flyer portion approaching and a baffle plate portion provided in front of the rectilinear discharge port, and insert the discharge cylinder portion, the flyer portion and the dispersion plate inside the skin. The method according to claim 4, wherein the foamable material is injected by injecting the foamable material into the discharge cylinder. At least one straight discharge port is opened at the tip of the discharge cylinder, and at least one straight discharge port is provided before the straight discharge outlet. Side discharge port (I) A dispersion plate having a flyer portion adjacent to the side discharge port and a baffle plate portion provided in front of the straight discharge port, and a skin opening formed on the funnel forming the IS. 5. The foaming material according to claim 4, wherein the foaming material is injected by inserting the discharge cylinder portion, the flyer portion and the dispersion plate into the interior of the skin in combination with an opening closing device for closing. The described method.