JPH0334955B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Technical Field of the Invention] The present invention relates to an apparatus for manufacturing a seat formed by integrally molding a skin and a foam material.

[Background technology]

FIG. 1 is a longitudinal sectional view of an apparatus for manufacturing an integrally molded seat prior to the present invention, and FIG. 2 is a perspective view of an integrally molded seat manufactured by this apparatus.
The illustrated device consists of an upper mold 3 having an upper wall 1 and a side wall 2, and a lower mold 6 having an uneven surface 5 equipped with vacuum suction holes 9 that bring a skin 4 into close contact with the skin 4 such as vinyl chloride leather. is clamped and fixed between the edge 7 of the upper mold 3 and the edge 8 of the lower mold 6, and the skin 4 is vacuum-suctioned from the vacuum suction hole 9 to remove the uneven surface 5 of the lower mold 6.
A foaming material such as polyurethane is injected into the space 10 defined by the upper mold 3 and the skin 4 in close contact with the uneven surface 5 and foamed, and after demolding, an integrally molded seat is obtained. be.

In such a conventional case, when manufacturing a bucket-shaped seat as shown in FIG.
The uneven surface 5 protrudes upward from the edge 8 to be fixed, so when the skin 4 is clamped and fixed between the edge 7 of the upper mold 3 and the edge 8 of the lower mold 6, the skin 4 It is difficult to stretch and keep it fixed in place. Therefore, the quality of the manufactured seats is not good, as the skin protrudes or is missing in some areas, or is sagging or bulging in some areas, and there is also variation in quality among individual products. As a result, conventional apparatus and methods were not suitable for manufacturing seats with deep-drawn shapes such as bucket shapes. Conventionally, in order to manufacture deep-drawn seats (for example, bucket-shaped seats), the skin is divided into several parts and then glued and sewn to the seat-shaped pads, which requires a complicated process. I needed it.

[Purpose of the invention]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide an apparatus for manufacturing an integrally molded seat that has uniform skin distribution, constant quality for each individual product, and can be manufactured using a simple process, in order to solve the conventional drawbacks. That's true.

[Summary of the invention]

The manufacturing apparatus for a seat with integral skin molding of the present invention includes a substantially flat and removable top lid, a rectangular ring shape corresponding to the four circumferential sides of the seat to be molded, and the periphery of the top lid is placed on the top periphery of the rectangular ring shape. and an annular side mold having an annular fixing surface facing the inner circumferential side, and an upper mold is constituted by the
A skin fixing mold is arranged below the annular side mold so as to be connectable and separable, and has an upper end fixing surface facing outward from the upper periphery that can be closed by facing the annular fixing surface. A lower mold that can move up and down relatively along the inner periphery of the annular side wall of the skin-fixed type,
The skin-fixing type has an uneven surface in its center that protrudes upward when its peripheral edge is at the same height as the upper circumferential edge of the skin-fixing type, and vacuum suction holes are provided in the uneven surface. It is arranged to be movable vertically relative to the lower part, and further includes an upper surface part and a side part sutured around the four circumferences thereof between the annular fixing surface of the annular side mold and the upper end fixing surface of the epidermis fixing mold. After fixing the epidermis by firmly pinching the epidermis near the suture,
A heating means for heating the upper surface part is disposed above the annular side mold from which the upper cover has been removed, and after the upper skin part is heated, the lower mold is raised relative to the skin fixed mold. The upper peripheral edge of the skin fixing mold and the peripheral edge of the lower mold are closed at the same height.

[Embodiments of the invention]

Next, a first embodiment of an apparatus for manufacturing an integrally molded seat according to the present invention will be described with reference to the drawings.

FIG. 3 is a longitudinal cross-sectional view of the first embodiment of the device of the present invention, showing a state in which the skin-fixing type, side type, lower type, and upper type are all closed.

FIG. 3a is an end view of a cut portion taken approximately along line A--A in FIG. 3. FIG.

FIG. 4 is a longitudinal sectional view showing a state in which the skin is fixed between the skin fixing mold and the side mold and heated.

FIG. 5 is a cross-sectional end view of a one-piece seat according to the present invention.

First, the skin 12 is coated on the upper peripheral edge of the annular skin fixing mold 11, which has vertically open side walls. The skin-fixing mold 11 has a flange 13 on the outer side of the lower end. The skin 12 is preferably formed by manufacturing the upper surface 41 and side surface 42 of the integrally molded seat skin 12 shown in FIG. 2 from different materials and condensing or joining them with a welder. The upper surface portion 41 is preferably made of vinyl chloride leather using a highly elastic backing material or a laminated fabric material such as vinyl chloride film to block air permeability. The side portion 42 is preferably made of ordinary vinyl chloride leather or fabric material that is inexpensive. By manufacturing the skin 12 from top and side portions 41 and 42, each having a different material or color, it is possible to vary the feel or appearance of the manufactured seat.

Next, the annular side mold 14 is attached to the epidermis fixing mold 11 to clamp the epidermis 12. The side mold 14 has a flange 18 on the outer side of the lower end, and when it is ring-attached to the skin fixed mold 11, the flange 18 is placed on the upper surface of the flange 13 of the skin fixed mold 11 to maintain the ring-attached state of the side mold 14. Assure. The skin 12 consists of an annular fixing surface 19 provided in the middle of the inner circumference of the side mold 14 and a skin fixing mold 11.
It is securely held between the upper end fixing surface 20 and the fixing position will not shift even when it is stretched.
The fixing position of the epidermis 12 is the side surface portion 42 of the upper surface portion 41.
This is the position adjacent to the sutured portion 43 between the two. Suture part 4
3 is located outside the fixed position, which means that the epidermis 12
When the skin is stretched and a force is applied inward to the skin fixing mold 11, the fixing state of the skin 12 is made more secure.

Next, the fixed upper surface part 41 of the epidermis is heated using the heating device 21.
(Figure 4). By heating appropriately, the upper skin portion 41 is easily denatured and molded easily, accurately and beautifully.

Next, a lower mold 24 having an uneven surface 23 with a plurality of vacuum suction holes 22 that brings the upper surface part 41 of the epidermis into close contact with the lower mold 24
Then, the skin fixing mold 11 is fitted to the outside from above, and the upper surface portion 41 is stretched and covered with the uneven surface 23. Normally, the lower mold 24 is fixed, and the flange 13 of the skin fixed mold 11 is lowered from above and placed on the upper surface of the flange 25 provided in the middle of the outer circumference of the lower mold 24. 24 and the skin fixing mold 11 are ensured, and the molding position is determined. The relative movement between the lower mold 24 and the skin-fixing mold 11 may be reversed as will be explained later in the second embodiment.

When the fitted state is secure, the airtight means 15 provided on the upper surface of the flange 25 of the lower mold 24 seals the upper skin part 41, the skin fixed mold 11, and the lower mold 24.
The space 31 defined by these is completely airtight. Further, since the upper skin portion 41 is heated and has extensibility, it is sufficiently expanded to cover the uneven surface 23 of the lower mold 24 . The vacuum suction hole 22 is bored perpendicularly to the concave surface 27 and communicates with a space 26 provided inside the lower mold 24 . The vacuum suction hole 22 has a concave surface 2
It is desirable that a plurality of holes be formed in positions where the upper surface portion 41 is difficult to make close contact with, such as a position adjacent to the convex surface 28 of No. 7. The space 26 is connected to a vacuum pump 30 via a conduit 29.
It is familiar to

Next, the air in the space 31 is sucked through the vacuum suction hole 22, and the upper surface part 41 of the epidermis is removed from the uneven surface 2 of the lower mold 24.
Close to 3. By operating the vacuum pump 30, the conduit 29, the space 26, the vacuum suction hole 2
The air in the space 31 is sucked through the upper surface 23, and the upper surface portion 41, which is heated and has extensibility, is easily deformed and molded in close contact with the uneven surface 23.

Next, the space 1 is formed by the upper surface part 41 of the skin that is in close contact with the uneven surface 23 of the side mold 14 and the lower mold 24.
Inject the foam material into 6. Suitable foam materials include polyurethane, vinyl chloride resin, and other equivalents.

After injecting the foam material, the upper mold 32 together with the side mold 14
The upper lid 33 constituting the mold is attached to the upper end of the side mold 14 to seal the space 16, and the foaming material is foamed.
The foam material is foamed to form the uneven surface 23 of the lower mold 24, the upper surface 34 of the skin fixing mold 11, and the inner surface 3 of the side mold 14.
5 and along the lower surface 36 of the upper lid 33.

After foaming, the operation of the vacuum pump 30 is stopped, the upper lid 33 is removed from the side mold 14, and the integrally molded foam body 44 with the skin 12 (see FIG. 5) is taken out from the lower mold 24 and the side mold 14. Since the upper mold 32 is constructed separately from the upper lid 33 and the side mold 14, the foam 44 can be easily taken out from the upper mold 32. In order to more easily remove the foam 44 from the lower mold 24, air may be sent into the upper skin portion 41 from the vacuum suction hole 22.

The integrally molded seat manufactured according to the present invention has a fifth
As shown in the end view of the cut section in the figure, the upper surface of the skin 41
However, the center portion, the slope portion 41a, and the peripheral portion 41b are faithfully stretched along the shape of the lower mold, and are closely integrated with the foam 44, without wrinkles, shifting, or peeling. The skin side surface portion 42 is not bonded to the side surface of the foam 44, but after demolding, its edge 45 is appropriately fixed to the underside of the seat to cover the side surface of the foam 44.

The apparatus of the first embodiment is suitable for manufacturing involving manual labor.

Next, the second part of the manufacturing apparatus for an integrally molded seat of the present invention will be described.
An example will be explained.

FIG. 6 is a longitudinal cross-sectional view of a second embodiment of the device of the present invention, and FIG. 6a is an end view of a section taken approximately along line B--B in FIG. 6.

FIG. 7 is a longitudinal sectional view showing a state in which the skin is fixed between the skin fixing mold and the side mold and heated.

The device of the second embodiment includes a fixed annular skin fixing mold 61, an annular side mold 64 ring-attached to the upper end of the skin fixing mold 61, and an upper mold 8 together with the annular side mold 64.
2 and a top cover 83 that is attached to the upper end of the side mold 64; and an uneven surface 73 that is fitted inside the fixed mold 61 and is movable up and down, and that is equipped with vacuum suction holes 72 that bring the epidermis 12 into close contact. a lower mold 74 and an epidermis 12
It basically consists of a means 21 for heating the air, and a vacuum pump 30 for sucking air from a vacuum suction hole 72.

First, the upper end of the fixed skin fixing mold 61 is covered with the skin 12. The epidermis 12 is similar to that described in the first embodiment. At this time, the lower die 74 is
It is necessary to move the uneven surface 73 downward to a position where it does not contact the epidermis 12. Lower mold 74
A shaft 93 is fixed to the bottom surface of the shaft 93, and the shaft 93 is connected to a vertical movement mechanism (not shown).

Next, the annular side mold 64 is attached to the skin fixing mold 61 to clamp the skin 12. The epidermis 12 is of the lateral type 6
4 and the upper end fixing surface 70 of the skin fixing mold 61, and the fixing position will not shift even when it is stretched. The fixing position of the epidermis 12 is the same as in the first embodiment.

Next, the fixed upper surface part 41 of the epidermis is heated using the heating device 21.
(Figure 7).

After heating, the lower mold 74 is moved upward to form an inner protrusion 91 provided on the inner periphery of the upper end of the skin fixing mold 61 and an outer recess 9 provided on the outer periphery of the lower side of the lower mold 74.
2 to determine the molding position. At this time, since the airtight means 75 is provided on the upper surface of the outer recess 92, the upper surface of the skin 41 and the skin fixed mold 6
The space 81 defined by 1 and the lower mold 74 is
It is completely airtight. Moreover, the upper surface part 41 of the epidermis is
Since it has extensibility when heated, it is sufficiently expanded to cover the uneven surface 73 of the lower mold 74. Vacuum suction hole 72
is the same as in the first embodiment.

Next, by operating the vacuum pump 30, the air in the space 81 is sucked through the conduit 79, the space 76 provided inside the lower mold 74, and the vacuum suction hole 72, and is heated to make it extensible. Top part 4
1 is easily deformed and molded in close contact with the uneven surface 73.

The following steps are the same as in the first embodiment.

The device of the second embodiment is primarily suitable for mass production.

[Effects of the Invention] In summary, according to the present invention, it is possible to fix the epidermis in a predetermined position with it fully stretched, and
The distribution of the epidermis is uniform and it has excellent dimensional stability, there is no uneven distribution of the epidermis such as protruding or insufficient epidermis, there is no wrinkles due to sagging or bulging, and the quality is consistent for each individual product. This makes it possible to manufacture an integrally molded seat that has the advantage of being manufactured through a simple process.

Further, since the upper mold is constructed separately from the upper lid and the side mold, it is easy to take out the foam from the upper mold.

Furthermore, the material of the integrally molded seat manufactured by manufacturing the skin from different materials,
It is possible to have a wide variety of colors, etc., and by using inexpensive materials for the side parts, it is also possible to manufacture the seat at a low cost.

The integrally molded seat manufactured using the present invention can be used in a wide range of fields in addition to automobile seats.

[Brief explanation of drawings]

FIG. 1 is a longitudinal sectional view of a conventional apparatus for manufacturing a one-piece seat. FIG. 2 is a perspective view of the manufactured one-piece seat. FIG. 3 is a longitudinal sectional view of a first embodiment of the device according to the invention. FIG. 3a is an end view of a section cut approximately along the line A--A in FIG. 3. FIG. FIG. 4 is a longitudinal sectional view showing a state in which the skin is fixed between the skin fixing mold and the side mold and heated. FIG. 5 is a cross-sectional end view of a one-piece seat according to the present invention. FIG. 6 is a longitudinal sectional view of a second embodiment of the device according to the invention. FIG. 6a is an end view of a section cut approximately along the line B--B in FIG. 6. FIG. FIG. 7 is a longitudinal sectional view showing a state in which the skin is fixed between the skin fixing mold and the side mold and heated. [Explanation of main symbols], 11, 61...Skin fixed type, 12...Skin, 14, 64...Side type, 2
2,72...Vacuum suction hole, 24,74...Lower mold,
23,73...Uneven surface, 30...Vacuum pump, 3
3,83...Top lid, 32,82...Top mold.

Claims (1)

[Claims] 1. A substantially flat and removable top cover 33, 83;
An annular side mold 14 having a square annular shape corresponding to the four circumferential sides of the seat to be molded, and having a portion on the upper periphery on which the periphery of the upper lid is placed, and annular fixing surfaces 19, 69 facing the inner periphery side. , 64 constitute the upper mold 32, 82, and has an annular side wall that is open at the top and bottom, and has an upper end fixing surface 20, 70 facing outward from the upper periphery that can be closed by facing the annular fixing surface. Fixed molds 11 and 61 are arranged so as to be removable and removable under the annular side mold, and are lower molds that can move up and down relatively along the inner periphery of the annular side wall of the skin fixed mold, the periphery of which is close to the skin. A lower mold 24, which has an uneven surface 23, 73 in the center that protrudes upward from the upper peripheral edge of the fixed mold when it is flush with the upper peripheral edge of the fixed mold, and vacuum suction holes 22, 72 are bored in the uneven surface; 74 is disposed below the skin fixing mold so as to be relatively vertically movable; The epidermis 12 consists of a side part 42 sutured to
After fixing the epidermis by firmly clamping the vicinity of the sutured part 43, the heating means 21 for heating the upper surface part 41 is
Placed above the annular side mold from which the upper lid has been removed, and after heating, raise the lower mold relative to the skin-fixed mold to close the upper periphery of the skin-fixed mold and the periphery of the lower mold at the same height. A manufacturing device for a seat integrally molded with a skin.