JPH0661771B2 - Method for manufacturing foam integrally molded with skin material - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for producing a foam integrally molded with a skin material, which is applied to mold a foam integrated with a skin material to be assembled as a cushion body of an automobile seat, for example. It is about.

2. Description of the Related Art Generally, when molding the above-mentioned foam integrally with a skin material, a bag-shaped skin material having a predetermined three-dimensional shape is used in advance, and this skin material is assembled in the cavity space of the lower mold. Position the terminal side on the mating surface of the lower mold, insert the terminal between each mating surface to clamp the upper mold to the lower mold, and then fill the inside of the skin material from the injection port of the upper mold. Resin is foamed in the cavity of the mold to form a foam integrally with the skin material.
-30121, JP-A-63-45007).

In this way, when the upper die is clamped by interposing the end of the skin material between the mating surfaces of the upper and lower molds, the skin material can be easily assembled in the cavity recess of the lower mold by aligning it with a predetermined three-dimensional shape. However, it is difficult to keep the sealing property of the cavity space completely airtight due to the thickness of the skin material that is sandwiched between the mating surfaces of the upper and lower molds. It is unavoidable that the foam material impregnates the skin material in a large amount.

On the other hand, conventionally, in addition to the upper and lower molds, a core mold is provided, and a skin material formed in a three-dimensional bag shape in advance is assembled and arranged in the cavity recess of the lower mold, and the end of this skin material is Cavity that is sandwiched between the core mold and the open / close mold of the lower mold, the upper mold is assembled so that the core mold is positioned in the mold and surrounded by the lower mold, and the mold is divided into the core mold and the lower mold. It has been proposed to form a foam integrally with the skin material by sealing the space in an airtight manner (Actual Kaihei No. 2-19514).

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention However, in the above-described method for manufacturing a foam integrally molded with a skin material, since the end of the skin material is sandwiched between the core mold and the upper mold open / close mold, molding having a complicated mold structure You must use a mold. Also, after assembling the skin material in the cavity recess of the lower mold and also assembling the core mold in the cavity space of the lower mold, place the end of the skin material on the upper surface side of the core mold and Since the end of the skin material is sandwiched between the core molds by closing the opening / closing mold, there is a possibility that the skin material cannot be shaped and assembled in a predetermined three-dimensional shape.

According to the present invention, the present invention is capable of maintaining the cavity space of the molding die in a completely airtight manner, and moreover, the entire shape including the end side of the skin material can be held in an accurate shape so that it can be easily assembled in the die. An object of the present invention is to provide a method for producing a foam integrally molded with a skin material, which can be integrally molded with a skin material.

Means for Solving the Problems In the method for producing a skin material-integrated molded foam according to the present invention, a desired width is continuously formed from the open end of the bag-shaped skin material having a predetermined three-dimensional shape to the inner circumference. A hooking edge is provided, and the hooking edge is applied and fixed to the upper surface side of the outer peripheral edge of the core mold so that the skin material is assembled from the outer peripheral edge of the core mold into a predetermined three-dimensional shape. Place this skin material and the core mold in the cavity recess of the lower mold, and lock the core mold on the mating surface of the lower mold with the locking piece that stands up from the upper surface side of the core mold. , The upper mold is placed on the mating surface of the lower mold, and the upper and lower molds containing the skin material and the core mold are closed and fixed to each other on the mating surfaces, and the inside of the skin material positioned in the mold is then fixed. The foamed resin filled in the foam is foamed to form a foam integrally with the skin material. It is possible to position and fix the lower mold by fitting the recessed groove and the locking piece.

Function In this method for producing a foam integrally molded with a skin material, the skin material is preliminarily supported in a bag shape by the core mold by applying and fixing the latching edge of the skin material to the upper surface side from the outer peripheral edge of the core mold. Since it is assembled in the cavity of the lower mold, the skin material can be easily assembled into the desired three-dimensional shape, and the mating surfaces of the upper and lower dies can be directly brought into direct contact with each other to secure the mold cavity completely. Therefore, it is possible to integrally form a good foam by keeping it airtight. In addition, since the core mold is positioned and fixed to the lower mold by fitting the recessed groove provided on the mating face of the lower mold and the locking piece, there is an obstacle when directly mating the mating faces of the upper and lower molds. In addition, the core mold can be accurately positioned on the lower mold and clamped and fixed on the upper mold.

Embodiments The following will be described with reference to the accompanying drawings.

As shown in FIG. 1, a method of manufacturing the foam integrally molded with the skin material uses a molding die 1 and forms a foam with a foam resin such as urethane foam integrally with a skin material 10 assembled inside the molding die 1. Has been applied to

As shown in FIG. 2, the skin material 10 has a main body portion 11 formed in advance in a predetermined three-dimensional bag shape. It can be formed using a sheet material such as leather. At the open end of the main body portion 11, a continuous latching edge portion 12 having a desired width is attached inside over the entire circumference.
The latching edge portion 12 is used as a terminal that is applied to and fastened to the core type as described later, and can also be attached as a skin portion that partially encloses the bottom surface side of the seat body. Notches 12a, 1 into which the base side of a locking piece projecting from a core mold, which will be described later, can be fitted into the latching edge portion 12
2b ... Can be provided at positions corresponding to the corners of the seat body, and a trim cord 13 used for hooking the skin material 10 to the core mold can be attached to the inner edge.

As the mold 1, a mold including a lower mold 2, an upper mold 3, and a core mold 4 is used. The lower mold 2 has a cavity recess 20 into which the skin material 10 is inserted, and the mating surface 21 is provided with a plurality of recessed grooves 22.22 ... For locking and fixing the core mold 4 with locking pieces to be described later. It is provided. This groove 22,2
It is preferable to provide 2 ... Corresponding to the corner position of the cavity recess 20 and to provide in the plane of the mating surface 21 that does not reach from the corner position to the outer peripheral edge. The upper mold 3 is provided with a foamed resin injection port (not shown) that is sealed by a freely openable / closable plug body 30 in the approximate center of the plate surface, and is projected around the circumference thereof to directly contact the mating surface 21 of the lower mold 2. A mating surface 31 is formed to be face-to-face. As the core mold 4, a substantially square downward-facing dish-like one is used, and an opening 41 having a rising flange portion 40 is formed at the center side thereof. In addition, the core mold 4 has concave grooves 22, 2 of the lower mold 2.
A plurality of locking piece portions 42, 42 ... Are provided so as to project outward from a corner position on the upper surface side so as to be positioned corresponding to 2. Further, as shown in FIGS. 3 and 4, a plurality of hook-shaped protrusions 44, 44, for locking the latching edge portion 12 of the skin material 10 are attached to the peripheral portion 43 of the core mold 4 at intervals. Has been. As shown in FIG. 5, the opening 41 of the core mold 4 is sealed by the convex portion 32 of the upper mold 3, and the convex portion 32 is formed.
Around the circumference of, there is provided a recess 33 that fits into the rising flange portion 40 of the core die 4.

In this molding die 1, first, the skin material 10 is set to the core die 4
Attach to. In assembling the skin material, the latching edge portion 12 is placed from the outer peripheral edge of the core die 4 to the upper surface side, and the trim cord 13 connected to the end of the latching edge portion 12 is attached to the core die 4 as described above. By engaging with the projecting pieces 44, 44, ..., The main body 11 of the skin material 10 can be formed into a predetermined three-dimensional bag shape and supported by the core mold 4. This shaping can be performed by assembling the skin material 10 to the core mold 4 and by allowing an operator to put his / her hand through the opening 41 of the core mold 4 and expand from the inner side. 12
It is also possible to make a contact with the upper surface of the core mold 4 so as to be placed by applying. Then, the skin material 10 is assembled with the core mold 4 into the cavity recess 20 of the lower mold 2. This assembling is performed by engaging piece portions 42, 42 ...
Is fitted into the concave grooves 22, 22 ... of the lower mold 2 and positioned, and as the core mold 4 is assembled to the lower mold 2, the skin material 10 has a predetermined shape as shown in FIG. It can be inserted into the cavity recess 20 of the lower mold 2 while maintaining its three-dimensional shape. When the upper mold 3 is placed on the lower mold 2 in this state, the upper and lower molds 2 and 3 are attached to the mating surfaces 2 as shown in FIG.
1, 1 and 31 can be directly brought into face-to-face contact with each other to securely fix the whole mold including the core die 4, and the mating faces 21 and 31 can be hermetically sealed by the packing member 34. At the same time, the opening portion 41 of the core die 4 has the rising flange portion 40.
Can be sealed by fitting with the recess 33 of the upper mold 3 and similarly air-tightly sealed by the packing member 35.
The cavity space of the molding die 1 surrounded by the upper die 3 and the core die 4 can be kept completely airtight. In this mold-clamped state, the latching edge portion 12 fixedly attached to the core die 4 of the skin material 10 has a peripheral portion 4 of the core die 4 as shown in FIG.
It is also possible to locate it inside the space 6 that is partitioned by 3 and the inner surface side of the upper mold 3.

In the molding die 1, if a foamed resin such as urethane foam is filled from the injection port of the upper die 3 into the skin material 10 inserted in the cavity space through the opening 41 of the core die 4, As shown in the figure, the foam 14 can be integrally foam-molded with the skin material 10. With this foam molding, the mold 1
Since the mating surfaces 21 and 31 of the upper and lower molds 2 and 3 are directly brought into face-to-face contact with each other and the molds are clamped and fixed in an airtight manner, cell roughness can be prevented. At the same time, it is possible to prevent the skin material 10 from being impregnated with the foamed resin, and normally to suppress the impregnation of about 3 mm to about 1 mm. Further, since the latching edge portion 12 of the skin material 10 is applied and fixed to the upper surface side of the core die 4, the skin material 1 which is partitioned by the inner surface side of the core die 4
Foam 14 can be formed in the body of the zero. Further, since the foamed resin can be prevented from moving into the space 6 defined by the inner surface of the upper mold 3 and the peripheral portion 43 of the core mold 4, the foamed body 14 is extremely good and maintains a predetermined three-dimensional shape. It is possible to accurately form it integrally with the skin material 10. By forming the lower side 45 of the core die 4 in the cavity space of the molding die 1 so as to project in the foam body 14, a receiving groove 15 for assembling the seat frame can also be formed. After the foam 14 is molded, the upper mold 3 is opened to form the recess 2 of the lower mold 2.
From 0 to the core mold 4, the foam 14 integrated with the skin material 10 can be removed from the mold, and the core mold 4 to the skin material 10 can be removed.
It is possible to obtain a foam integrally molded with the skin material 10 by removing the hooking edge portion 12 of the.

In the embodiment described above, the core mold 4 is attached to the locking piece portions 42, 4
The description has been given based on the case where the core mold 4 is assembled and fixed to the lower mold 2 in step 2, but one side of the core mold 4 is detachably attached to the lower mold 2 with a link or the like, and the locking piece portion 42 is provided on the other side. The lower mold 2 may be assembled. Further, although the above-described embodiment exemplifies the case where the cushion foam for a seat is integrally formed with the skin material, the present invention can be applied to integrally forming a headrest or various foamed resin molded products with the skin material. it can.

EFFECTS OF THE INVENTION As described above, according to the method for producing a skin material-integrally molded foam according to the present invention, the entire surface is kept in a predetermined shape by the skin material, and the foamed resin does not ooze to the surface side, which is excellent. This makes it possible to extremely easily form a foam having a different cell state integrally with a skin material.

[Brief description of drawings]

FIG. 1 is an exploded perspective view of a molding die to which the method for producing a foam according to the present invention is applied, FIG. 2 is a perspective view of a skin material assembled to the molding die, and FIG. 3 is a core die of the molding die. FIG. 4 is an explanatory view showing a skin material assembled, FIG. 4 is an explanatory view showing a core mold assembled to a lower mold of the same mold, and FIG. 5 is an explanatory view showing an upper mold of the same mold assembled. FIG. 6 is an explanatory view showing an enlarged space in which the end of the skin material is located in the same molding die, and FIG. 7 is an explanatory view showing a foamed state of the same molding die. 1: Mold, 2: Lower mold, 20: Cavity recess, 21:
Mating surfaces, 22, 22 ...: Grooves, 3: Upper mold, 31: Mating surface, 4: Core mold, 42, 42 ...: Locking piece, 10: Skin material, 12: Latching edge, 14 : Foam.

Claims (2)

[Claims] 1. A latching edge portion (12) having a desired width is provided from the open end of a bag-shaped skin material (10) having a predetermined three-dimensional shape to the inside of the entire periphery, and the latching edge portion is provided. (12) to the core type (4)
The outer surface of the core mold (4) is attached to the upper surface of the core mold (4) so as to have a predetermined three-dimensional shape from the outer periphery of the core mold (4). ) And core type (4)
A locking piece which is inserted into the cavity recess (20) of the lower mold (2) and stands up from the upper surface side of the core mold (4) which is disengaged from the latching edge (12) of the skin material (10). Core type (4) in part (42, 42 ...)
Is fixed to the mating surface (21) of the lower die (2), and the upper die (3) is placed on the mating surface (21) of the lower die (2) to cover the skin material.
(10) and core molds (4) with each mold (2,
3) After the mating surfaces (21, 31) are clamped and fixed to each other, the foam resin filled inside the skin material (10) located in the mold (2, 3) is foamed to form the skin material (10 ) Is integrally formed with the foam (14), the method for producing a foam integrally molded with a skin material. 2. The recesses (21, 21 ...) Provided on the mating surface (21) of the lower mold (2) and the locking pieces (42, 42 ...) of the core mold (4) are fitted together. The method for producing a foam according to claim 1, wherein the core mold (4) is positioned and fixed to the lower mold (2).