JP6066293B2 - Skin-integrated foam-molded product and manufacturing method thereof - Google Patents

Description

The present invention relates to a skin-integrated foam-molded product formed by injecting a foamed resin raw material into a bag body formed by stitching together a plurality of skin pieces and foam-molding a core portion, and a method for manufacturing the same .

  Conventionally, as this type of skin-integrated foam-molded product, a bag body is a two-piece projection that protrudes into the bag body by overlapping the edges of two skin pieces among a plurality of skin pieces. And both lateral ends of the two-piece protrusion are sewn to the inner surface of the bag body, and the horizontal intermediate portion of the two-piece protrusion serves as a raw material injection port for injecting the foamed resin raw material. Is known (for example, Patent Document 1).

Japanese Patent No. 4837478 (FIGS. 2 and 3)

  However, the above-described conventional skin-integrated foam-molded product has a problem that the foamed resin material leaks due to the opening of the material injection port during foam molding.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a skin-integrated foam-molded article capable of preventing leakage of a foamed resin material and a method for producing the same.

  As a result of examining the cause of the opening of the raw material inlet, the present inventor has obtained knowledge that there is a cause in the sewing stage of the bag body. That is, the sewing of the bag body is a bag surface constituting part that forms a surface having a raw material inlet of the bag body by spreading the above-mentioned two skin pieces on both sides of the two-piece protrusion in a crotch-open state, The bag body is sewn together with the bag main body constituting all the surfaces other than the surface constituted by the bag surface constituting portion. At this time, the bag body is sewn in an inverted state with the back surface of the skin piece facing outward, and a two-piece protrusion is sewn on the outer surface of the bag body in the inverted state. Here, the bag surface constituting portion and the bag main portion are usually configured such that the entire outer edge portion of the bag surface constituting portion is overlapped with the opening edge of the bag main portion so as to circulate around the opening edge of the bag main portion in one direction. Therefore, both end portions in the lateral direction of the two-piece protrusions are tilted in the opposite directions and sewn, so that the raw material inlet is easily twisted and opened.

Therefore, the inventor of the present application has completed the inventions of the following claims 1 to 8 based on the above findings.

In other words, the manufacturing method of the skin-integrated foam-molded product according to the invention of claim 1 is a skin-integrated foam formed by injecting a foamed resin material into a bag formed by sewing a plurality of skin pieces together and foam-molding the core portion. a method of manufacturing a foamed molded article to form a two-piece projections to the part of the edge portions of the multiple skin piece 2 ply projecting to the inside of the bag body, next to the two pieces projection at the direction of the intermediate portion, to separate the edge portions of the skin piece foamed resin material to form a raw material inlet for injecting into the bag body, the two skin pieces constituting the two pieces projection two pieces Forming a bag surface constituting part that forms a surface having a raw material inlet in the bag body in a crotch-open state on both sides of the protrusion, and all of the bag body other than the face constituting the bag surface constituting part Forming the bag main part constituting the surface of the bag, and the entire outer edge of the bag surface constituting part of the bag with the reverse side of the plurality of skin pieces facing outward Overlaid on the opening edge of the body part, the opening edge of the bag main body part is sewn to the outer edge part of the bag surface constituting part so as to circulate in one direction, thereby forming a bag body in an inverted state. When forming a bag body that is turned over and turned upside down , both ends in the lateral direction of the two-piece protrusions are tilted to the same side, and the opening edge of the bag main body part is the outer edge of the bag surface constituent part. incidentally sewing the parts, both end portions of the lateral two pieces protrusion also has a feature at that sewn on the back of the bag.

Invention of Claim 2 is the manufacturing method of the skin-integrated foam-molded article according to Claim 1, wherein the length of the two-piece protrusions in the protruding direction of both lateral ends of the two-piece protrusions is 8 mm or more. It is characterized in that it is formed as follows.
According to a third aspect of the present invention, in the method for manufacturing a skin-integrated foam-molded article according to the first or second aspect, the two-piece protrusion is formed in a shape in which the ends of both end portions in the lateral direction are notched in a square shape. However, it has characteristics.
According to a fourth aspect of the present invention, in the method for producing a skin-integrated foam-molded product according to any one of the first to third aspects, the skin-integrated foam-molded product is formed into an L-shape as viewed from the side. It is characterized in that the entrance is a headrest disposed on the bottom surface.
The skin-integrated foam-molded product according to the invention of claim 5 is a skin-integrated foam-molded product obtained by injecting a foamed resin raw material into the bag body and foam-molding the core portion, and constitutes a bag body sewn together. The two edge portions of the plurality of skin pieces are overlapped to form a two-piece protrusion that protrudes inside the bag body, and both lateral ends of the two piece protrusions are folded down to form the bag body. Skin-integrated foam molding that is sewn on the inner surface and the intermediate part in the lateral direction of the two-piece protrusion is the raw material injection port for injecting the foam resin material into the bag by separating the edges of the skin pieces In the product, the bag body is a bag surface constituting a surface having a raw material inlet in the bag body by spreading two skin pieces constituting the two-piece protrusion in a crotch-open state on both sides of the two-piece protrusion. A plurality of skin pieces consisting of a component and a bag main body constituting all surfaces of the bag body other than the surface constituted by the bag surface component. Is turned upside down after being sewed upside down, and the entire outer edge of the bag surface component is overlapped with the opening edge of the bag main body, and circulates around the opening edge of the bag main body in one direction. The lateral end portions of the two-piece protrusions are tilted to the same side, wrap around the opening edge of the bag main part, and the bag surface constituent part and the bag main part are stitched together. It is characterized in that it is sewn to the surface facing the inside of the bag body by the thread.

The invention according to claim 6 is characterized in that, in the skin-integrated foam-molded product according to claim 5 , the length in the protruding direction of both end portions in the lateral direction of the two-piece protruding portion is 8 mm or more.

The invention according to claim 7 is characterized in that, in the skin-integrated foam-molded article according to claim 5 or 6 , the two-piece protrusion is formed by cutting off the tip of both end portions in the lateral direction into a square shape.

The invention of claim 8 is the skin-integrated foam-molded product according to any one of claims 5 to 7 , wherein the skin-integrated foam-molded product has an L-shape in a side view and the raw material inlet is a bottom surface. It has the feature in the place made into the headrest arrange | positioned.

[Inventions of Claims 1 to 8 ]
In the manufacturing method of the skin-integrated foam-molded article according to claim 1 and the skin-integrated foam-molded article according to claim 5 , both end portions in the lateral direction of the two-piece protrusions are tilted to the same side and sewn to the inner surface of the bag body. Therefore, twisting of the raw material inlet can be suppressed. Thereby, at the time of foam molding, it is possible to prevent the raw material inlet from opening, and to prevent leakage of the foamed resin raw material.

Here, the bag, the entire outer edge of the bag surface component is superimposed on an opening edge of the bag main body portion, Ru sewn so as to surround the opening edge of the bag main body portion in one direction. According to invention of Claim 1, 5 , sewing can be made quick and the improvement of production efficiency is aimed at.

Further, as in the inventions of claims 2 and 6 , if the length in the projecting direction of the two end portions in the lateral direction of the two piece projecting portion is 8 mm or more, the bag body in the both end portions in the lateral direction of the two piece projecting portion. It is possible to increase the sewing strength to the inner surface of the two and maintain the state in which the two end portions in the lateral direction of the two-piece protrusion are tilted to the same side. Thereby, it becomes possible to further prevent the foamed resin raw material from leaking by further suppressing the twist of the raw material inlet.

Further, as in the inventions of claims 3 and 7 , if the two-piece protrusions are configured such that the tips of both ends in the lateral direction are notched in a square shape, the two pieces constituting the two-piece protrusions When the skin pieces are stitched together, the edges of the two skin pieces are easily aligned.

In addition, a headrest, an armrest, a console box, etc. are mentioned as a skin-integrated foam-molded product of the present invention and a skin-integrated foam-molded product manufactured by the manufacturing method of the present invention . In particular, as in the fourth and eighth aspects of the invention, when the skin-integrated foam-molded product is a headrest having an L-shaped side view and the raw material inlet arranged on the bottom surface, the raw material inlet is twisted. Since the influence becomes large, many benefits of the present invention can be received.

Headrest perspective view Cross section of headrest Perspective view of bag Side cross-sectional view of a bag set in a foam mold Perspective view of the bag in an inverted state Perspective view of bag surface constituent part and bag main part (A) The top view of the two skin pieces which comprise a two piece protrusion, (B) The perspective view of a bag surface structure part Top view of the bag body upside down Perspective view of two-piece protrusion Top view of the bag body in an inverted state according to the reference embodiment

  Hereinafter, an embodiment in which the present invention is applied to a headrest will be described with reference to FIGS. As shown in FIGS. 1 and 2, the headrest 10 according to the present embodiment has a head-shaped main body 11 with a top portion of a gate-shaped stay 12 embedded therein, and a leg 12 </ b> A of the stay 12 from the bottom surface of the headrest main body 11. 12A has a hanging structure and is attached to a rear seat 90 of the vehicle. In detail, the headrest main body 11 is long in the front-rear direction and has an L shape in a side view in which a front end portion is bent downward.

  As shown in FIG. 2, the headrest main body 11 has a structure in which a core portion 14 made of foamed resin is covered with a bag body 20. As shown in FIG. 3, the bag body 20 is formed by stitching a plurality of skin pieces 15, and circular stay insertion holes 17, 17 and a raw material inlet 16 extending in the width direction of the bag body 20 are formed on the bottom surface. I have. The core part 14 is obtained by foaming the foamed resin raw material 36 (see FIG. 4) inside the bag body 20.

  Next, the bag body 20 will be described in detail. The bag body 20 is obtained by sewing a plurality of skin pieces 15 into a bag shape so that the back surface faces outward (see FIG. 5), and turning the bag body 20 upside down so that the seam allowance is on the inside. (See FIG. 3). Specifically, as shown in FIG. 6, the bag body 20 includes a bag surface forming portion 21 that forms a bottom surface, and a bag main body portion 22 that forms a container and forms a surface other than the bottom surface. The bag surface constituting portion 21 and the bag main portion 22 are sewn together with the outer edge of the bag surface constituting portion 21 being superimposed on the opening edge 22A of the bag main portion 22.

  As shown in FIG. 3, the bag surface constituting portion 21 is formed by sewing a pair of skin pieces 15 and 15, and has the above-described raw material inlet 16 at the joint portion between the pair of skin pieces 15 and 15. Yes. A pair of stay insertion holes 17 and 17 are provided on the side of the raw material inlet 16. In addition, as shown in FIG. 5, in order to prevent leakage of the foamed resin material 36 (see FIG. 4) from the stay insertion holes 17, 17, the back surface of the bag surface constituting portion 21 is surrounded by the stay insertion holes 17, 17. Block-like sponges 17A and 17A are fixed.

  Specifically, the bag surface constituting portion 21 is a joint portion of the pair of skin pieces 15 and 15, and the edge portions 15 </ b> A and 15 </ b> A of the skin pieces 15 and 15 are overlapped and turned over. A two-piece protrusion 25 protruding inside the bag body 20 is provided. And the edge parts 15A and 15A of a pair of skin pieces 15 and 15 which comprise the two piece protrusion 25 are sewn on the both sides of a horizontal direction, and the intermediate part of the horizontal direction of the two piece protrusion 25 was mentioned above. A raw material inlet 16 is formed. The pair of edge portions 15A and 15A are overlapped so that the end surfaces 15M and 15M (see FIG. 7B) are flush with each other.

  Further, as shown in FIGS. 5 and 9, the two-piece protrusion 25 is such that both end portions in the lateral direction are tilted to the same side, and both end portions are the inner surfaces of the bag body 20 (in FIGS. The inner surface of the body 20 faces outward).

  The bag surface component 21 is manufactured as follows. In order to manufacture the bag surface constituting portion 21, first, as shown in FIGS. 7A and 7B, a pair of skin pieces 15 and 15 are overlapped so that the back surface faces outside, The edge portions 15A and 15A of the skin pieces 15 and 15 are sewn together at both lateral portions. And a pair of skin pieces 15 and 15 are spread in the crotch-opening state on both sides of the stitched portion, and the bag surface constituting portion 21 is formed. At this time, a two-piece protrusion 25 is formed by a pair of edge portions 15A and 15A that are stitched together and overlapped.

  Here, the edge portions 15A and 15A of the pair of skin pieces 15 and 15 have L-shapes in which both side portions in the horizontal direction are composed of a seam extending in the horizontal direction from an end portion in the horizontal direction and a seam extending in the vertical direction connected thereto. Are sewn at the seam 18 and can be separated from each other at the lateral intermediate portion of the two-piece projection 25 (see FIG. 3). Thereby, the above-described raw material inlet 16 is formed in the intermediate portion in the lateral direction of the two-piece protrusion 25.

  Specifically, as shown in FIG. 7 (A), the edge 15A of each skin piece 15 is provided with notches 15K and 15K formed by notching both ends in the lateral direction in a square shape. By aligning the vertical and horizontal sides of the portion 15K, the pair of skin pieces 15, 15 can be easily positioned. The pair of edge portions 15A and 15A are sewn in an L shape along the cutout portion 15K.

  Further, a distance d between the seam 18A extending in the lateral direction of the L-shaped seam 18 between the pair of edge portions 15A and 15A and the edge of the skin piece 15, that is, the side of the two-piece protrusion 25 The length in the protruding direction of both ends of the direction is 8 mm or more. In the present embodiment, as described above, since the notches 15K and 15K are provided at both ends in the lateral direction of the edge 15A of the skin piece 15, the length from the seam 18A to the notch 15K. However, it is 8 mm or more.

  The above is the description of the manufacturing method of the bag surface constituting part 21. As described above, the bag surface constituting part 21 is sewn to the bag main body part 22 with the outer edge of the bag surface constituting part 21 superimposed on the opening edge 22A of the bag main body part 22 (see FIG. 6). The bag body 20 in an inverted state is obtained (see FIG. 5). In the present embodiment, as shown in FIG. 8, the bag surface constituting portion 21 circulates around the opening edge 22A (see FIG. 6) of the bag main body portion 22 in one direction (clockwise direction in FIG. 8). Can be sewn.

  Here, as shown in FIG. 9, when the bag surface constituting portion 21 is sewn to the bag main body portion 22, the two-piece projecting portion 25 has a pair of skin pieces 15, with both lateral end portions thereof being brought down to the same side. 15 is superposed on one skin piece 15 (left skin piece 15 in the example of FIG. 9), and is sewn to the opening edge 22 </ b> A of the bag main body portion 22 together with the one skin piece 15.

  As described above, since the length in the protruding direction of both end portions in the lateral direction of the two-piece protruding portion 25 is 8 mm or more, the two-piece protruding portion 25 and one skin piece 15 are connected by three needles. You can sew more. Thereby, the sewing strength to the one skin piece 15 of the two piece protrusion part 25 can be enlarged, and the state which fell the both ends of the horizontal direction of the two piece protrusion part 25 to the same side can be hold | maintained.

  When the bag body 20 in an inverted state is obtained, the bag body 20 is turned upside down using the raw material inlet 16. As a result, the two-piece protrusion 25 is in a state in which both end portions in the lateral direction are sewn to the inner surface of the bag body 20 turned upside down.

  The description regarding the structure of the headrest 10 of this embodiment is above. Next, a method for manufacturing the headrest 10 will be described.

  In order to manufacture the headrest 10, as shown in FIG. 4, the bag body 20 is set in the foaming mold 30 so that the bottom face faces upward. At this time, the stay 12 is set in a state where the top portion is accommodated in the bag body 20 and the leg portions 12A and 12A extend upward through the stay insertion holes 17 and 17 (see FIG. 3).

  Next, the foamed resin raw material 36 is injected from the raw material inlet 16 of the bag body 20. And the core part 14 is foam-molded by foaming and expanding the foamed resin raw material 36 by heating the foam molding die 30. Thereby, the headrest 10 is obtained. The raw material injection port 16 is pushed and closed by the foamed resin raw material 36 that expands and expands.

  Here, as in a conventional skin-integrated foam-molded product, when both end portions in the lateral direction of the two-piece projection 25 are tilted opposite to each other and sewn on the inner surface of the bag body 20, during foam molding, The raw material inlet 16 formed in the intermediate portion in the lateral direction of the two-piece protrusion 25 is easily twisted and opened. As a result, there arises a problem that the foamed resin material 36 leaks from the bag body 20.

  However, in this embodiment, since both ends in the lateral direction of the two-piece protrusion 25 are tilted to the same side and sewn to the inner surface of the bag body 20, twisting of the raw material inlet 16 can be suppressed. Thereby, it is suppressed that the raw material inlet 16 opens at the time of foam molding, and leakage of the foamed resin raw material 36 can be prevented.

  Further, since the length in the protruding direction of both ends in the lateral direction of the two-piece projecting portion 25 is 8 mm or more, the both ends in the lateral direction of the two-piece projecting portion 25 are sewn to the inner surface of the bag body 20. It is possible to increase the strength and maintain the state where both end portions in the lateral direction of the two-piece protrusion 25 are tilted to the same side. Thereby, the twist of the raw material injection port 16 can be further suppressed, and the leakage of the foamed resin raw material 36 can be prevented.

[Other Embodiments]
The present invention is not limited to the above-described embodiment. For example, the embodiments described below are also included in the technical scope of the present invention, and various modifications are possible within the scope of the invention other than the following. It can be changed and implemented.

( 1 ) The length in the projecting direction of both lateral ends of the two-piece projecting portion 25 may be increased without providing the notches 15K and 15K at both lateral ends of the two-piece projecting portion 25. .

( 2 ) In the above embodiment, the present invention is applied to the headrest 10 that is L-shaped in a side view and the raw material inlet 16 is disposed on the bottom surface. However, other headrests, armrests, console boxes You may apply to. At this time, if the influence of the twist of the raw material injection port 16 at the time of foam molding is small, the length in the projecting direction of both end portions in the lateral direction of the two-piece projecting portion 25 may be 8 mm or less.

( 3 ) In the said embodiment, although the bag surface structure part 21 formed only the bottom face of the bag body 20, you may form a bottom face and a part of side surface.
[Reference embodiment]
Although not belonging to the technical scope of the present invention, the skin-integrated foam-molded product that can achieve the same effects as those of the above-described embodiment may have the following configuration.
(1) The bag surface constituting portion 21 and the bag main portion 22 may be sewn so as to circulate in one direction opposite to the one direction of the opening edge 22A of the bag main portion 22. Specifically, as shown in FIG. 10, sewing may be performed in the directions of arrows A and B starting from point P.

10 Headrest (Skin integrated foam molding)
14 Core part 15 Skin piece 15A Edge part 15K Notch part 16 Material inlet 20 Bag body 21 Bag surface structure part 22 Bag main part 25 Two piece protrusion part 36 Foamed resin raw material

Claims (8)

A method for producing a skin-integrated foam-molded product obtained by injecting a foamed resin raw material into a bag formed by stitching together a plurality of skin pieces and foam-molding a core part,
And a part of the edge portions of the plurality of skin pieces 2 ply to form a two-piece projection which protrudes on the inside of the bag,
At the lateral middle portion of the two pieces projection, the foamed resin material to form a raw material inlet for injecting into the bag body by separating the edge portions of the skin piece,
The two skin pieces constituting the two-piece protrusion are spread on both sides of the two-piece protrusion so as to form a bag surface constituting part constituting the surface of the bag body having the raw material inlet. As well as
Forming a bag main body constituting all surfaces of the bag body other than the surface constituting the bag surface constituting portion;
The entire outer edge portion of the bag surface constituting portion is overlaid on the opening edge of the bag main body portion in an inverted state in which the back surfaces of the plurality of skin pieces face outward.
By sewing the opening edge of the bag main body portion to the outer edge portion of the bag surface constituting portion so as to circulate in one direction, the bag body in the inverted state is formed, and the bag body is turned over,
When forming the bag body in the inverted state, both ends in the lateral direction of the two-piece protrusions are tilted to the same side, and the opening edge of the bag main body portion is formed on the bag surface constituting portion. incidentally stitching the outer edge, the two pieces lateral end portions the manufacturing method of the integral skin foam molded article, characterized in that that sewn on the back of the bag of the projection. 2. The skin-integrated foam-molded article according to claim 1, wherein the two-piece protrusion is formed such that a length in a protruding direction of both end portions in the lateral direction of the two-piece protrusion is 8 mm or more. Manufacturing method. 3. The method for producing a skin-integrated foam-molded product according to claim 1, wherein the two-piece protrusion is formed in a shape in which a front end of each lateral end is cut out in a square shape. 4. The said skin-integrated foam-molded product is a headrest having an L-shape in a side view and the raw material injection port being disposed on the bottom surface. A method for producing a skin-integrated foam molded product. It is a skin-integrated foam-molded product formed by injecting a foam resin material into a bag body and foam-molding the core part,
Two edge portions of a plurality of skin pieces constituting the bag body sewn together are overlapped to form a two-piece protrusion protruding inside the bag body, The both ends of the lateral direction are tilted and sewn to the inner surface of the bag body, and the lateral intermediate part of the two-piece projection is separated from the edges of the skin pieces to convert the foamed resin material into the In the skin-integrated foamed molded product that became the raw material injection port for injection into the bag body,
The bag body is formed by expanding two skin pieces constituting the two-piece protrusion in a crotch-open state on both sides of the two-piece protrusion, and constituting a surface having the raw material inlet in the bag body. It consists of a bag surface constituting part and a bag main part constituting all surfaces other than the face constituting the bag surface constituting part of the bag body, and the back surfaces of the plurality of skin pieces are in an inverted state in which they face outward. After being sewn, it is turned upside down, and the entire outer edge of the bag surface component is overlapped with the opening edge of the bag main body, and is sewn so as to circulate around the opening edge of the bag main body in one direction. The configuration is
Both end portions in the lateral direction of the two-piece protrusion are tilted to the same side, and circulate around the opening edge of the bag main body portion to sew the bag surface configuration portion and the bag main body portion with a thread that sews the bag surface configuration portion. Of these, the skin-integrated foam-molded product, which is sewn on a surface facing the inside of the bag. The skin-integrated foam-molded article according to claim 5, wherein a length in a protruding direction of both end portions in the lateral direction of the two-piece protruding portion is 8 mm or more. 7. The skin-integrated foam-molded product according to claim 5, wherein the two-piece protrusions are formed by cutting off the ends of both end portions in the lateral direction into a quadrangular shape. The said skin-integrated foam-molded product is a headrest in which the raw material inlet is disposed on the bottom surface in an L-shape when viewed from the side, according to any one of claims 5 to 7. Skin integrated foam molding.

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