JPH0698633B2 - Method for manufacturing foamed mold and skin-integrated foamed product - Google Patents

Description

TECHNICAL FIELD The present invention relates to a mold for foam molding and a method for producing a skin-integrated foam product using the mold.

[Prior Art] In some foam products, a skin material is joined to the surface of the foam. As a method for manufacturing a foamed product of this type, there is a method in which a foam is formed in a mold and at the same time, a skin material set in the mold is joined to the surface of the foam. Hereinafter, the foamed product manufactured by this method is referred to as a skin-integrated foamed product.

The drawings of FIGS. 5 to 7 show a conventional method for producing a foam product integrated with a skin. The skin-integrated foamed product in this example is the seat of an automobile seat.

As shown in FIG. 5, the foam molding die 1'includes a lower die 2 and an upper die 3 '. First, the skin material 4 is arranged on the upper side of the lower mold 2, the peripheral portion of the skin material 4 is fixed to the flange portion 2c of the lower mold 2 by the clamp device 5, and the skin material 4 is vacuumed in this state. The two molding surfaces 2a and the division surface 2b are brought into close contact with each other. Next, the lower mold 2 and the upper mold 3'are clamped to form a cavity 6 between the upper mold 3'and the skin material 4, and a foaming resin is filled in the cavity 6 for foaming to form a foam 7 '. To form. At the same time, the foam 7'is joined to the skin material 4 facing the cavity 6, and the foam 7'and the skin material 4 are integrated. After this, the foam 7 ′ integrated with the skin material 4
Was taken out from the mold 1'and post-treated, but at that time, the following problems occurred.

[Problems to be Solved by the Invention] When the mold 1'is clamped, a part of the skin material 4 is arranged along the dividing surface 2b of the lower mold 2 and the dividing surface 3b 'of the upper mold 3'. However, it is almost impossible to bring the dividing surface 3b 'of the upper mold 3'and the skin material 4 into contact with each other completely without a gap, and a slight gap connecting to the cavity 6 is formed between them. Therefore, when the foam molding is performed, the foamable resin penetrates into the gap to generate a burr protruding outward.
The gap is very narrow, and the foamable resin hinders foaming in the gap, so the burr tends to be very hard. Incidentally, FIG. 6 shows the skin material 4 and the foamed body 7 ′ immediately after being taken out from the mold 1 ′, and the reference numeral 8 in the figure is a burr.

After being taken out from the mold 1 ', as shown in FIG. 7, the frame 9 is attached to the recess 7a' of the foam 7 ', and the non-bonding portion 4a of the skin material 4 which is not bonded to the foam 7'is removed. Surface of foam 7'formed by molding surface 3a 'of upper mold 3'
7b ', and the end of the non-bonded portion 4a is covered with the frame 9
Then, the seat portion B'of the vehicle seat A'shown in FIG. 8 is completed.

However, when the burr 8 is present in the foamed body 7 ′, when the post-treatment is performed as described above, the burr 8 portion projects outward together with the skin material 4 and the protrusion 10 is formed, which is very attractive. It had the drawback of getting worse. Further, as described above, since the burr 8 is hard, there is a drawback that the protrusion 10 remarkably reduces the feel of the seat portion B '.

On the other hand, as described above, the non-bonded portion 4a of the skin material 4 is covered with the foam 7 '.
There is also a method of removing the burr 8 before covering the front surface 7b 'of the above, but since the burr 8 adheres to the back surface of the skin material 4, it was very difficult to cleanly remove it. Also, burr 8
However, even if it was taken cleanly, the removed mark was hard, and it was not possible to improve the point that the feel of the seat portion B ′ was lowered. Further, if such a troublesome process is added to the manufacturing process, there is also a disadvantage that productivity is lowered.

The present invention has been made in view of the above-mentioned problems of the conventional technique, and an object thereof is to provide a foam molding die and a skin-integrated foam product that can contribute to the quality improvement of the skin-integrated foam product. It is about to provide a manufacturing method.

[Means for Solving the Problems] The present invention has been made to achieve the above object,
The gist is (1) a foam molding die described below,
(2) A method for manufacturing a foam product integrated with a skin.

(1) Having a first mold and a second mold, arranging a skin material along a molding surface and a dividing surface of the first mold, and combining the skin material and the second mold. In the foam molding die used to foam the foamable resin in the cavity formed between the foam material and the foam material, and at the same time to bond the foam material to the skin material, molding of the second mold. A mold for foam molding, wherein the surface is provided with a ridge protruding toward the cavity side and connected to the divided surface along the divided surface.

(2) In a method for producing a skin-integrated foamed product in which a skin material is joined to the surface of a foam, the foam molding mold according to claim 1 is used, and the molding surface of the first mold is used. A skin material is arranged along with, and the edge portion of this skin material is arranged along the dividing surface of the first mold and the second mold and clamped, and the skin material and the second mold are The foamable resin is foamed in the cavity formed between the two to form a foam, and at the same time, the foam is bonded to the skin material arranged along the molding surface of the first mold, After opening, cover the surface of the foam formed by the molding surface of the second mold with the skin material sandwiched between the split surfaces of the first mold and the second mold, When
A burr made of a foamable resin generated between the split surface of the second mold and the skin material is housed in an annular groove formed in the foam by the protrusion of the second mold. A method for producing a skin-integrated foamed product characterized by the above.

[Operation] Due to the protrusion provided on the second mold, an annular groove is formed in the foam along the dividing surface of the mold.

After taking out the foam and the skin material partially bonded to the foam from the mold, when covering the non-bonded portion of the skin material that is not bonded to the foam on the surface of the foam, the second The burr generated between the divided surface of the mold and the skin material is housed in the groove. This prevents the burr and the skin material covering the burr from protruding outward.

[Embodiment] An embodiment of the present invention will be described below with reference to the drawings from FIG. 1 to FIG. The skin-integrated foamed product in this embodiment is also the seat portion of the automobile seat, as in the prior art. The same aspects as those in the above-mentioned conventional technique will be described with the same reference numerals.

FIG. 1 shows a closed state of the foam molding die 1.
The foam molding die 1 is composed of a lower die (first die) 2 and an upper die (second die) 3. The lower mold 2 is no different from the conventional one. The upper die 3 has a part of its structure different from the conventional one. A protrusion 3d that projects toward the cavity 6 is provided on the molding surface 3a of the upper mold 3 which is continuous with the dividing surface 3b. The ridge 3d is wound along the dividing surface 3b. The size of the ridge 3d is appropriately determined by assuming the size of the burr 8 described later in advance.

The method of forming the foam 7 by the foam molding die 1 and simultaneously joining the foam 7 to the skin material 4 is the same as the conventional method. That is, the skin material 4 made of a polyvinyl chloride sheet is arranged on the upper side of the lower mold 2, and the peripheral portion of the skin material 4 is fixed to the flange portion 2c of the lower mold 2 by the clamp device 5. In this state, the skin material 4 is evacuated to bring the skin material 4 into close contact with the molding surface 2a and the division surface 2b of the lower mold 2. Next, the upper mold 3 is put on the lower mold 2, and the portion of the skin material 4 arranged along the dividing surface 2b of the lower mold 2 is divided into the dividing surface 2b of the lower mold 2 and the dividing surface of the upper mold 3. Insert it between 3b and tighten the mold. Then, a cavity 6 formed between the molding surface 3a of the upper mold 3 and the skin material 4 is filled with urethane-based foamable resin and foamed to form a foam 7. At this time, the foam 7 is bonded to the skin material 4 arranged along the molding surface 2a of the lower mold 2, and the foam 7 and the skin material 4 are integrated.

FIG. 2 is an enlarged cross-sectional view of an essential part of the skin material 4 and the foamed body 7 integrated as described above, and shows a state immediately after being taken out from the foam molding die 1. On the outer peripheral surface of the foam body 7, a joint portion 4b of the skin material 4 which is joined to the foam body 7
An annular groove 7c is formed along the boundary with the non-bonded portion 4a that is not bonded to. Needless to say, the groove 7c is formed by the protrusion 3d of the upper mold 3 and has a structure not found in the conventional foam 7 '.

On the other hand, a burr 8 is formed at the root portion of the non-bonding portion 4a of the skin material 4. The process of forming the burr 8 is the same as that of the conventional one, and the burr 8 is formed on the dividing surface of the upper mold 3 during foam molding.
The foaming resin is formed in a slight gap between 3b and the skin material 4.

After this, as shown in FIG. 3, the frame 9 is attached to the recess 7a of the foam 7, and the non-bonding portion 4a of the skin material 4 is attached to the upper mold 3.
The surface 7b of the foamed body 7 formed by the molding surface 3a is extended to the frame 9 and fixed to the frame 9. At this time, the burr 8 is housed in the groove 7c of the foam 7, and the burr 8 portion does not project outward.

FIG. 4 is a perspective view of a vehicle seat A having a seat portion B manufactured in this manner. Compared with the conventional seat portion B ', the appearance of the seat portion B is very clean, and the presence of the burr 8 cannot be recognized from the outside. or,
When the outer skin of the seat B is touched from the outside, the presence of the burr 8 cannot be felt because there is no protrusion. Therefore, the appearance and feel of the seat portion B are much better than before, and the sense of quality is further enhanced.

The present invention is not limited to the above-mentioned embodiment and various modes can be adopted.

For example, the foam product integrated with the skin is not limited to the seat portion of the automobile seat, but may be the back portion of the automobile seat,
It may be something other than an automobile seat.

Further, in the above-mentioned embodiment, the method of vacuuming is adopted as the method of setting the skin material along the molding surface and the dividing surface of the first mold, but it may be set by other methods. .

The material of the skin material is not limited to polyvinyl chloride, but may be another resin, or a tricot or fabric made of synthetic fiber or natural fiber. The form of the skin material is not limited to the sheet form, and may be sewn.

Further, the material of the foam is not limited to the urethane resin, and various foaming resins can be adopted.

[Effects of the Invention] As described above, the present invention has the excellent effects described below.

By foam-molding a foamable resin with the mold for foam molding of the present invention, a foam having an annular groove for accommodating burrs can be manufactured along the dividing surface of the mold.

Then, after opening the mold for foam molding, when covering the surface of the foam with a portion of the skin that is not joined to the foam, between the split surface of the second mold and the skin. By accommodating the generated burr in the groove of the foam, the burr portion does not project outward. As a result, the presence of burrs becomes visually unrecognizable, and the presence of burrs is no longer felt when the epidermis is touched from the outside. Therefore, the appearance and feel of the skin-integrated foamed product are much better than in the past, and the superior effect is further enhanced.

[Brief description of drawings]

The drawings from FIG. 1 to FIG. 4 show an embodiment of the present invention, and FIG. 1 shows a state in which a foaming mold according to the present invention is clamped and foamable resin is foam-molded. The sectional view shown in FIG. 2, FIG. 2 is an enlarged sectional view of an essential part of the foam and the skin material immediately after being taken out from the mold, FIG. 3 is an enlarged sectional view of an essential part after the end treatment of the skin material, and FIG. It is a perspective view of a vehicle seat. 5 to 8 show the prior art, FIG. 5 is a sectional view corresponding to FIG. 1, FIG. 6 is an enlarged sectional view of an essential part corresponding to FIG. 2, and FIG. FIG. 8 is a cross-sectional view of the skin material after the end treatment, and FIG. 8 is a perspective view of a conventional automobile seat. 1 ... Mold for foam molding, 2 ... Lower mold (first mold), 2a ... Molding surface, 2b ... Dividing surface, 3 ... Upper mold (second mold), 3a ... Molding surface, 3b ... Dividing Surface, 3d ... Ridge, 4 ... Skin material, 6 ... Cavity, 7 ... Foam, 7c ... Groove, 8 ... Burr, B ... Seat (skin integrated foam product).

Claims (2)

[Claims] 1. A first mold and a second mold, wherein a skin material is arranged along a molding surface and a dividing surface of the first mold, and the skin material and the second mold. A foam molding die used to form a foam by foaming a foamable resin in a cavity formed between the second mold and a foam molding mold used for joining the foam to the skin material. A mold for foam molding, wherein the molding surface is provided with a ridge protruding toward the cavity side and continuous with the split surface along the split surface. 2. A method for producing a skin-integrated foamed product in which a skin material is joined to the surface of a foam, wherein the foam molding die according to claim 1 is used to mold the first die. While arranging the skin material along the surface, the edge portion of this skin material is arranged along the dividing surface of the first mold and the second mold and clamped, and the skin material and the second Foamable resin is foamed in the cavity formed between the molds to form a foamed body, and at the same time, the foamed body is bonded to the skin material arranged along the molding surface of the first mold. After the mold is opened, the surface of the foam formed by the molding surface of the second mold is covered with the skin material sandwiched between the divided surfaces of the first mold and the second mold. , At that time,
A burr made of a foamable resin generated between the split surface of the second mold and the skin material is housed in an annular groove formed in the foam by the protrusion of the second mold. A method for producing a skin-integrated foamed product characterized by the above.