JPH06341B2 - Method for manufacturing foam-molded product with integral skin - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial field of application) The present invention relates to a skin-integrated foam-molded article in which a foaming raw material is injected into a skin material installed in a molding die and the raw material is foamed in the skin material. Manufacturing method.

(Prior Art) Like headrests or armrests for automobiles,
In many cases, a so-called integral foam molding method is used for producing a foam-molded article obtained by covering a foam with a skin material, from the viewpoint of workability and appearance of the resulting molded article.

In the conventional method for manufacturing a headrest or the like by the integral foam molding method, a skin material having a predetermined bag shape provided with a hole or an opening for injecting a foaming raw material is installed in a molding die, and the foaming raw material is filled with the hole or the opening. After pouring into the skin material from the above part, the hole is closed with a cap or the opening is closed by overlapping the opening edge of the skin material, foaming is performed inside the skin material, and a foam molded product integrated with the skin material Is manufactured.

(Problems to be Solved by the Invention) However, the work of closing the hole or opening for injecting the raw material must be performed in a short time in consideration of the reaction rate of the raw material. For this reason, the cap is displaced from the proper position due to urgent work, or the work mistake is likely to occur due to the flow of the foaming raw material that foams in the skin material, causing the opening edge of the skin material to fold and wrinkle and overlap. However, the seal of the hole or opening for injecting the raw material is likely to be incomplete. As a result, the raw material in the skin material may leak from the portion and stain the outer surface of the skin material, impairing the aesthetics of the molded product. Even if the raw material does not leak, the aesthetic appearance of the molded product may be impaired due to the fact that the opening edge portion of the skin material is likely to be wrinkled.

The present invention is intended to solve the problems of the prior art, that is, it is difficult to obtain a skin-integrated foam-molded article having a good appearance.

(Means for Solving Problems) The present invention relates to a method for producing a skin-integrated foam-molded article in which a foaming raw material is injected into a skin material installed in a molding die, and foaming is performed in the skin material. The opening edge of the material is opened outward and sandwiched by a part of the molding die, and a raw material is injected from the opening of the skin material formed thereby to form a foam, and a foam surface under the opening. It is characterized in that a groove is formed in the groove, and then the edge of the opening of the skin material is locked in the groove.

(Function) The skin material in the molding die according to the present invention is in a state in which the periphery of the opening is sandwiched by a part of the molding die. Therefore, even if the raw material leaks from the opening, it does not adhere to the skin material around the opening sandwiched by the molding die, and there is no risk of the outer surface of the skin material being contaminated with the raw material. Then, after the foaming is completed, the molded product is released from the mold and the opening is covered with the opening edge portion sandwiched by the molding dies, whereby a predetermined skin-integrated foamed molded product can be obtained. Furthermore, since the edge of the skin material opening is locked in the groove formed on the foam surface below the opening,
The edges will be hidden, and the appearance of the opening will be extremely good.

(Example) This invention is demonstrated based on an Example below.

The drawings relate to an embodiment of the present invention. FIG. 1 is a sectional view showing a state in which the headrest skin material 10 is installed in a molding die 12, and FIG. 2 is a perspective view of a molded product after demolding. The figure is a sectional view of the headrest taken along the line AA.

The skin material 10 is a fabric, plastic leather, or a laminated body thereof, a laminated body of a fabric and a flexible foam, or a laminated body of a fabric, a flexible foam and a plastic film, or the like, and various sheet-shaped materials having a predetermined bag shape. In this structure, a part of the bottom portion, that is, the opening edge portions 10a and 10b can be opened and expanded outward, and the opening portion 10c is formed. The holes 10d on both sides of the opening 10c are for inserting the stay 14. The stay 14 is for immediately mounting the headrest, and is integrated with a reinforcement body (not shown) embedded in the foam body 15. The stay 14 and the reinforcing body are collectively called an insert.

The molding die 12 comprises a lower die 12a, a middle die 12b and an upper die 12c, and a cavity 11 having the same shape as the headrest is formed inside when the die is closed. The lower die 12a has a shape having an opening for fitting the middle die 12b in a portion corresponding to the opening 10c of the skin material. The middle die 12b has such a shape that when it is fitted in the opening of the lower die 12a, the opening edges 10a, 10b of the skin material can be sandwiched between the lower die opening periphery 13a and the middle die 12b. Has an opening 13b for fitting the upper mold 12c. The upper die 12c has the cavity protrusion 13c.
As shown in FIG. 3, the protrusion 13c is formed on the part of the skin material 10a, 10a.
groove for accommodating the terminal of b and the engaging parts of the terminal
16a is for forming the foam 16.

When manufacturing a headrest, first insert the insert in which the reinforcement body and the stay 14 are integrated from the opening 10c of the skin material to the skin material.
Insert within 10. Next, the skin material 10 is attached to the lower mold 12a and the middle mold 12b. The device of the outer skin 10 is such that a part of the outer skin material 10, that is, the opening edges 10a and 10b are opened outward and expanded, and the opening edges 10a and 10b are sandwiched between the lower die opening peripheral surface 13a and the middle die 12b. Done in. Then, a foaming raw material such as a urethane foam raw material is injected into the skin material 10 through the opening 10c of the skin material 10, and the above 12c is fitted into the opening 13b of the middle die 12b to close the molding die 12 to foam the raw material. I do. Then, after foam molding, a molded product as shown in FIG. 2 is molded. Demold this,
By covering the opening 10c with the skin material edges 10a and 10b around the opening 10c as shown in FIG. 3, a predetermined headdress can be obtained. The ends of the skin material edges 10a and 10b covering the openings, that is, the opening edges, are closed by an engaging means such as adhesive bonding, a surface-bonding tape, or a string, and are locked and stored in the concave groove 16a of the foam. It

(Effects of the Invention) In the present invention, a part of the skin material is opened outward and sandwiched by a part of the molding die, and the raw material is injected through the opening of the skin material molded by the mold. Therefore, even if the raw material injected into the skin material leaks from the skin material opening, the skin material around the opening is sandwiched by the molding die, so that the skin material in the sandwiched portion is the raw material. Is not adhered, the outer surface of the skin material is not likely to be contaminated with the raw material, and a skin-integrated molded product having a good appearance can be obtained.

Further, according to the present invention, since the work of overlapping the opening edge portion of the skin material immediately after the raw material injection is unnecessary, even if the reaction rate of the raw material is fast, it is possible to perform the work without causing a problem, It is possible to improve production efficiency and reduce defective products. Furthermore, since a groove is provided on the foam surface below the opening and the edge of the opening for locking the edge of the skin material opening is concealed in the groove, the appearance can be made very good. .

[Brief description of drawings]

The drawings relate to an embodiment of the present invention. FIG. 1 is a sectional view showing a state in which a headrest skin material is mounted on a molding die, FIG. 2 is a perspective view of a molded product after demolding, and FIG.
It is sectional drawing cut | disconnected by the A line. Explanation of symbols 10 ... skin materials 10a, 10b ... opening edge 10c ... skin material opening 10d ... stay insertion hole 11 ... cavity 12 ... molding die 12a ... Lower mold 12b ・ ・ ・ Medium mold 12c ・ ・ ・ Upper mold 13a ・ ・ ・ Lower mold opening peripheral surface 13b ・ ・ ・ Medium mold opening 13c ・ ・ ・ Upper mold protrusion 14 ・ ・ ・ Stay 16 ・ ・ ・Foam 16a: Groove of foam

Claims (1)

[Claims] 1. A method for producing a skin-integrated foam-molded article in which a foaming raw material is injected into a skin material having a predetermined bag shape set in a molding die, and foaming is performed in the skin material. The outer part is opened outward and the opening edge part is sandwiched by a part of the molding die, and the raw material is injected from the opening part of the skin material formed thereby to form a foam and foaming under the opening part. A method for producing a skin-integrated foam-molded article, comprising forming a concave groove on a body surface and then locking the edge of the skin material opening portion in the concave groove.