JP3739516B2 - Mold for molding hard cotton and molding method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a mold for a hard cotton molded body that can be suitably used for a cushion material for a vehicle seat, and a method for producing a hard cotton molded body using the mold.
[0002]
[Prior art]
Conventionally, urethane foam has been frequently used as a cushion material for vehicle seats. This urethane foam is difficult to recycle, and has a problem that toxic gas such as cyan gas is generated when incinerated. Therefore, Japanese Patent Laid-Open No. 5-208470 proposes a cushioning material using sheet-like hard cotton obtained by mixing and compressing a polyester fiber and a low-melting-point polyester composite fiber at a predetermined ratio instead of urethane foam. ing. Since this hard cotton can be recycled, it does not need to be disposed of and has excellent properties such as good air permeability. Therefore, the use as a cushioning material etc. is anticipated against the background of the request | requirement of environmental conservation.
[0003]
[Problems to be solved by the invention]
However, when such hard cotton is molded using a mold having a mold surface that follows the outer shape of the molded body as in the prior art, as shown in FIG. 11, the corner portion R that curves into the convex shape of the molded body is formed. There is a problem that sink marks occur and a desired convex shape (solid line) along the inner surface of the mold cannot be obtained. That is, as shown by the broken line in FIG. 11, the corner portion R ′ does not advance sufficiently. Further, the corner portion R ′ tends to have insufficient strength.
[0004]
The present invention has been made in order to solve the above-described problems, and a molding die capable of producing a hard cotton molding having a desired convex shape and sufficient strength at a corner portion curved in a convex shape, and It aims at providing the shaping | molding method.
[0005]
[Means for Solving the Problems]
In order to achieve the above object, the molding die according to claim 1 is for molding a hard cotton molding having a convexly curved corner portion, and has a concave space having a large number of ventilation holes on a wall surface. And a male mold that has a large number of ventilation holes on the wall surface and that is inserted into the female mold to form a space according to the thickness of the hard cotton molding between the female mold inner surface and the female mold. And at least one side wall of the female mold is configured such that an inner surface is formed in a shape along the convexly curved corner portion and can be opened outward, and the male mold is disposed inside the female mold. closable der inward Ru in the inserted state.
[0006]
According to the mold of claim 1, the hard cotton sheet is inserted into the concave space of the female mold in a state in which the side wall where the inner surface is formed in a shape along the corner of the female mold is curved. Further, the male mold is inserted into the female mold and the hard cotton sheet is pressed. When the open side wall of the female mold is closed while the hard cotton sheet is pressed, at least a part of the hard cotton sheet is pressed between the male mold and curved in a convex shape following the inner surface of the side wall. It becomes the corner part. By supplying hot air to the hard cotton sheet in this state via the vent holes and then allowing to cool, a hard cotton molded body having a desired convex shape and a corner portion having sufficient strength is formed.
[0007]
The mold according to claim 2 is the mold according to claim 1, wherein a non-porous skirt member is joined to an outer periphery of each side wall of the female mold, and the side wall configured to be openable is It is connected to the bottom wall of the female mold so as to be freely opened and closed by hinge connection. Therefore, the hinge connection allows the side wall to be opened and closed easily, and the molding operation can be made more efficient. Moreover, the cold air etc. can be efficiently supplied to a hard cotton molding by the skirt member provided in the outer periphery of each side wall at the time of shaping | molding a hard cotton molding.
[0008]
Molding method according to claim 3, using the mold according to claim 1 or 2, a method of molding Katawata molded product having a corner portion that is curved in a convex shape, the female of the convex An insertion step of inserting a cotton sheet into the female concave space with the side wall formed with an inner surface formed in a shape along a corner portion curved in a curved shape, and the hard cotton sheet by the insertion step A pressing step of inserting the male mold into the inserted female mold and pressing the hard cotton sheet, and a side wall of the female mold opened in a state where the hard cotton sheet is pressed by the pressing process And bending the part of the hard cotton sheet into a convex shape following the inner surface of the side wall, and the female and male vent holes to the hard cotton sheet bent by the bending process. And a heating step of supplying hot air through.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings. FIG. 1 is an overall perspective view of a female die 1 as a mold according to an embodiment of the present invention, and FIG. 2 is a cross-sectional view taken along the line II-II in FIG.
[0010]
The female die 1 has a rectangular box shape, and four side walls 3A to 3D and a bottom wall 3E are formed by the punching panel 3 in which a large number of through holes 32 functioning as ventilation holes are formed. Of the four side walls 3A to 3D, the non-perforated side plates 2A to 2C are welded to the outer periphery of the punching panel 3 with a slight gap on the three side walls 3A to 3C except the front side of FIG. . The upper ends of the side plates 2 </ b> A to 2 </ b> C are formed as flange portions 21 bent outward, and a flange portion 81 of a male mold 7 to be described later is brought into contact with the flange portion 21.
[0011]
Hinges 4 are provided at a plurality of longitudinal positions on the open side edge of the punching panel 3 constituting the bottom wall 3E, and a movable side wall 3D comprising the punching panel 3 is rotatably connected to the hinges 4. Has been. As shown in FIG. 2, the movable side wall 3D has an arc cross section that is curved with a predetermined curvature. At the time of molding, the movable side wall 3D is pivotally closed upward as shown by a chain line in FIG. A concave space S surrounded by 3C and the movable side wall 3D is formed. A non-porous side plate 2D is welded to the outer periphery of the movable side wall 3D while keeping a slight gap along the outer peripheral surface of the movable side wall 3D.
[0012]
A known locking tool 5A having a hook piece 51 is provided on the outer surface of each of the side plates 2A to 2C. Further, the movable side plate 2D is provided with a locking member 5B having the same structure as that of the locking member at the center, and engagement rings 6B (see FIG. 1) are provided at both left and right ends thereof. The engagement ring 6B is engaged with the hook piece 51 of the locking tool 5A provided on the side of the movable side wall 2D of the side plates 2A and 2C when the movable side wall 3D is pivotally closed.
[0013]
3 is an overall perspective view of the male die 7 of the molding die, and FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. The male mold 7 has an outer shape along the plan view of the concave space S of the female mold 1, and the outer periphery thereof is bordered by an L-shaped frame member 8 having one side as a flange portion 81. A pressing body 9 formed in a container shape with a certain depth is joined to the frame member 8 at its opening edge. The pressing body 9 is constituted by a punching panel in which a large number of through holes 91 functioning as air holes are formed. At the center of each side of the frame member 8, an engagement ring 6 </ b> A is provided outward, and a beam having a rectangular cylindrical cross section is formed by connecting the support bases 61 of the engagement ring 6 </ b> A provided on the opposite side. Materials 62 and 63 are laid in a cross shape.
[0014]
Each surface of the punching panel constituting the side walls 3A to 3D of the female mold 1, the bottom wall 3E, and the pressing body 9 of the male mold 7 in order to facilitate the release of the hard cotton molded body after molding. Is coated with a fluororesin.
[0015]
Next, a molding process of a hard cotton molding using the molding die configured as described above will be described. As shown in FIG. 5, first, the hard cotton sheet H is inserted into the upper surface of the bottom wall 3E of the female mold 1 with the movable side wall 3D (movable side plate 2D) opened. The hard cotton sheet H has a large sheet area and is inserted in a state of protruding from the female mold 1. For this reason, the side edge part H1 by the side of the movable side wall 3D of the hard cotton sheet H also protrudes and extends from the inner surface of the movable side wall 3D.
[0016]
Here, with reference to FIG. 10 (A) and (B), the laminated hard cotton used as the hard cotton sheet H is demonstrated. For example, the laminated hard cotton is configured as follows. That is, tow (wisteria) polyester fiber (2 to 100 denier, 5 to 10 cm) is mixed with 5 to 40% by weight of core-sheath tow polyester composite fiber (2 to 100 denier, 5 to 10 cm). To produce sheet-like hard cotton H01 to H04 as shown in FIG. The hardness of each of the hard cottons H01 to H04 is 10 degrees, 15 degrees, 25 degrees, and 30 degrees (measured with an Asker F type hardness meter manufactured by Kobunshi Keiki Co., Ltd.), and the density is 0.02 to 0.05 g / cm. The range.
[0017]
The sheath of the composite fiber is a low-melting point copolymer polyester manufactured by pipe-in pipe or the like by mixing isophthalic acid during polycondensation. Therefore, by laminating the above hard cottons H01 to H04 in order from the smallest hardness and passing hot air of 100 to 200 ° C., the sheath of the composite fiber is melted and the polyester fibers are knotted together. As the volume decreases, a formable hard cotton sheet H whose hardness increases in order from the lower layer to the upper layer is formed (FIG. 10B).
[0018]
After inserting the hard cotton sheet H formed in this way into the female mold 1, as shown in FIGS. 6 and 7, the male mold 7 is inserted into the female mold 1, and each side plate 2A of the female mold 1 is inserted. The tip of the hook piece 51 of the locking tool 5A provided on ˜2C is hooked on the engagement ring 6A provided on the male mold 7, and the operation lever 52 of the locking tool 5A is returned to its original position. Thereby, the male mold 7 is strongly pushed into the female mold 1, and the hard cotton sheet H is compressed between the bottom surface of the pressing body 9 of the male mold 7 and the bottom wall 3 </ b> E of the female mold 1.
[0019]
As shown in FIG. 8, in this state, the movable side wall 3D is rotated upward with the hinge 4 as a rotation center, and the tip of the hook piece 51 of the locking tool 5B provided on the movable side plate 2D is attached to the male mold 7. It hooks on the provided engagement ring 6A. Further, the tip of the hook piece 51 of the locking member 5A provided on the side plates 2A and 2C of the female mold 1 is hooked on the engagement ring 6B provided on the movable side plate 2D, and the opening portion of the female mold 1 is completely closed. .
[0020]
As shown in FIG. 9, at this time, the side edge portion H1 of the hard cotton sheet H is sandwiched between the side surface of the pressing body 9 of the male mold 7 and the inner surface of the movable side wall 3D, and the inner surface is pressed by the pressing body 9. And the outer surface of the side edge portion H1 is curved following the inner surface of the movable side wall 3D.
[0021]
In this state, hot air at 100 to 220 ° C. is passed through the hard cotton sheet H through the many through holes 91 and 32 from the upper side of the male die 7 to the lower side of the female die 1 for 10 to 180 seconds. After the supply of hot air is stopped, it is allowed to stand for 20 to 180 seconds, and then a large number of through holes 91 and 32 are formed from the upper side of the male die 7 to the lower side of the female die 1 by sucking air from below the female die 1. The cool cotton sheet H heated by the hot air is cooled. In addition, non-perforated side plates 2A to 2D are provided on the outer periphery of the side walls 3A to 3D of the female mold 1, and these side plates 2A to 2D function as skirt members for guiding hot air and cold air. Therefore, hot air and cold air can be efficiently passed through the hard cotton sheet H inserted into the female mold 1 and the male mold 7 by these skirt members 2A to 2D.
[0022]
After the passage of the cold air, the male mold 7 and the female mold 1 are separated, and the molded hard cotton molded body is taken out. Then, the corner portion R (FIG. 11) on the outer surface of the hard cotton molded body is formed into a desired convex shape shown by the solid line in FIG. 11 without causing sink marks (broken lines in FIG. 11). Further, the strength of the corner portion R is sufficient.
[0023]
The present invention has been described above based on the embodiments. However, the present invention is not limited to the above embodiments, and various modifications can be easily made without departing from the spirit of the present invention. It can be guessed.
[0024]
For example, in this embodiment, one of the four side walls 3A to 3D of the female mold 1 is configured to be openable and closable, but two or more side walls may be configured to be openable and closable. Further, the side wall 3D is connected to the bottom wall 3E using the hinge 4, but the side wall 3D may be configured to be detachable instead of the hinge mechanism.
[0025]
Further, a slight gap was provided between the side walls 3A to 3D formed by the punching panel 3 of the female mold 1 and the side plates 2A to 2D joined to the outer periphery thereof. However, the side walls 3A to 3D and the side plates 2A to 2D may be brought into close contact with each other without providing the gap.
[0026]
【The invention's effect】
By using the molding die of the hard cotton molding of the present invention and the molding method thereof, there is an effect that a hard cotton molding having a desired convex shape and sufficient strength can be manufactured at a corner portion that is curved in a convex shape. is there.
[Brief description of the drawings]
FIG. 1 is an overall perspective view in a state in which a female movable side wall according to an embodiment of the present invention is opened.
FIG. 2 is a cross-sectional view taken along the line II-II in FIG.
FIG. 3 is an overall perspective view of a male mold.
4 is a cross-sectional view taken along line IV-IV in FIG.
FIG. 5 is an overall perspective view of a female mold in a state where a hard cotton sheet is inserted.
FIG. 6 is an overall perspective view of a molding die in a state where a male die is inserted into a female die.
7 is a cross-sectional view taken along line VII-VII in FIG.
FIG. 8 is an overall perspective view of a molding die with a movable side wall closed.
9 is a cross-sectional view taken along line IX-IX in FIG.
FIG. 10 is a sectional view schematically showing a hard cotton sheet.
FIG. 11 is a partial enlarged cross-sectional view showing an outline of a molded body.
[Explanation of symbols]
1 Female mold 2A, 2B, 2C Side plate (skirt member)
2D movable side plate (skirt member)
3 Punching panel 3A, 3B, 3C Side wall 3D Movable side wall 3E Bottom wall 32 Through hole (vent hole)
4 Hinge 7 Male 9 Pressing body 91 Through hole (vent hole)
H Hard cotton sheet H1 Side edge (part of hard cotton sheet)
R Corner part S Recessed space

Claims (3)

In a molding die for molding a hard cotton molding having a convex curved corner part,
A female mold that forms a concave space having a large number of ventilation holes on the wall;
A male mold that has a large number of air holes on the wall surface and that is inserted into the female mold to form a space according to the thickness of the hard cotton molding between the female mold inner surface,
At least one side wall of the female mold has an inner surface formed in a shape along the convexly curved corner portion and is configured to be openable outward, and the male mold is inserted into the female mold. mold Katawata molded body, wherein closable der Rukoto inwardly in state. A non-porous skirt member is joined to the outer periphery of each side wall of the female mold, and the releasable side wall is connected to the bottom wall of the female mold so as to be freely opened and closed by a hinge connection. 2. A mold for molding a hard cotton molded article according to claim 1. In a molding method for molding a hard cotton molded body having a corner portion that curves in a convex shape using the molding die according to claim 1 or 2,
An insertion step of inserting a hard cotton sheet into the concave space of the female mold in a state in which a side wall formed with an inner surface is formed in a shape along the convexly curved corner portion of the female mold;
A pressing step of pressing the hard cotton sheet by inserting the male mold into the female mold in which the hard cotton sheet is inserted by the inserting step;
In the state where the hard cotton sheet is pressed by the pressing step, the opened side wall of the female mold is closed, and a curve that curves a part of the hard cotton sheet in a convex shape along the inner surface of the side wall. Process,
And a heating step of supplying hot air to the hard cotton sheet bent by the bending step through the female and male vent holes.

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