JP2008142925A - Manufacturing method of foamed resin molded product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a foamed resin molded product capable of holding a subsidiary material such as a fibrous material or the like to the inner surface of a mold by an easy and inexpensive technique without degrading characteristics of the fibrous material. <P>SOLUTION: Magnetic yarn 5 among the subsidiary material 4 is sewn to a region facing a magnet 3 by a sewing machine or the like and the magnetic yarn 5 is magnetically attracted to the magnet 3 to hold the sheetlike subsidiary material 4 to the inner surface of an upper mold 1 as a whole in a close contact state. After a urethane raw solution is supplied in a lower mold 2, the upper mold 1 to which the subsidiary material 4 is magnetically attracted is mounted to the lower mold 2 to be clamped with the lower mold 2 and urethane is heated and foamed. After foaming, the molds are opened to demold a molded product. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a foamed resin molded product applied to a method for molding a seat pad of an automobile, and more particularly to a method for manufacturing a foamed resin molded product in which auxiliary materials such as a fiber-based material are integrally molded.

  As an automobile seat pad, there is one in which a subsidiary material such as a fiber material is integrated with a resin foam such as polyurethane foam. As a molding method for integrating such a fiber material with a resin foam, JP-A-2001-252930 gives magnetism to a fiber material made of polyester fiber or acrylic fiber and uses a magnet provided in a mold. A method is described in which a fiber material is held on the inner surface of a mold and foam-molded.

In the same publication, as a method of imparting magnetism to the fiber material, a method of mixing magnetic powder such as iron powder in the binder of the fiber material, or a magnetic powder layer bonded and integrated with the fiber material layer And a method of replacing 10-30% of the fibers of the fiber-based material with metal fibers.
JP 2001-252930 A

  Among the above-mentioned magnetism imparting methods, the method of mixing magnetic powder into the binder of the fiber-based material cannot impart sufficient magnetism unless the magnetic powder is mixed in the binder in an extremely large amount and the amount of binder used is remarkably increased. However, if it does in this way, there exists a possibility that the suppleness of a fiber type material may be impaired, or magnetic powder may fall off from a product.

  There is a similar problem in the method of bonding and integrating the magnetic powder layer with the fiber material.

  Even in the method of using magnetic fibers as part of the fibers of the fiber material, the flexibility of the fiber material may be impaired. In addition, blending or knitting synthetic resin fibers such as polyester fibers or acrylic fibers and metal fibers significantly increases the manufacturing cost of the fiber-based material. Moreover, when 10-30% of metal fibers having a large specific gravity are used, the weight of the fiber-based material is considerably increased. If the ratio of the metal fibers is reduced, the fiber material cannot be sufficiently magnetized, and it is difficult to hold the fiber material firmly on the inner surface of the mold.

  The present invention solves the above-mentioned conventional problems, allows auxiliary materials such as fiber materials to be held on the inner surface of the mold by an easy and inexpensive method, and also reduces the properties of the fiber materials. It aims at providing the manufacturing method of a foaming resin molding which is not.

  The method for producing a foamed resin molded article of the present invention (Claim 1) is a foamed resin molded article in which the secondary material is integrated by holding the secondary material on the inner surface of the mold and foaming the foamed resin stock solution in the mold. A foamed resin molding in which magnetism is imparted to the secondary material, a magnetic body is installed in the mold, and the secondary material is held on the inner surface of the mold by the magnetic force of the magnetic body In the method for manufacturing a product, magnetism is imparted to the auxiliary material by sewing magnetic fibers to the auxiliary material.

  The method for producing a foamed resin molded article according to claim 2 is characterized in that, in claim 1, the foamed resin is a urethane foam resin.

  According to a third aspect of the present invention, there is provided a method for producing a foamed resin molded product according to the first or second aspect, wherein the magnetic fiber is a magnetic metal fiber.

  The method for producing a foamed resin molded article according to claim 4 is characterized in that, in any one of claims 1 to 3, a magnet is attached to the inner surface of the mold, and the magnetic fiber is magnetically attached to the magnet. To do.

  According to a fifth aspect of the present invention, there is provided a method for producing a foamed resin molded product according to the fourth aspect, wherein the magnetic fiber is sewn in a region of the auxiliary material facing the magnet.

  According to a sixth aspect of the present invention, there is provided a method for producing a foamed resin molded product according to any one of the first to fifth aspects, wherein the auxiliary material is made of a fiber material.

  In the present invention, magnetism is imparted to the secondary material by sewing magnetic fibers to the secondary material. Therefore, for example, by sewing many magnetic fibers only in the vicinity of the magnet facing the mold side, the secondary material can be held firmly in the mold without affecting the characteristics of the secondary material as a whole. Can be provided with sufficient magnetism.

  In addition, since the sewing of the magnetic fiber is performed on the existing secondary material, the secondary material itself can be a popular product and the cost is low.

  Further, even if the position of the magnet is different for each mold, the secondary material can be magnetically attached to the mold by sewing the magnetic fiber at a position corresponding to the magnet of the mold.

  As the secondary material, a fiber-based material is suitable because it is easy to sew magnetic fibers.

  Of these fiber materials, by sewing the magnetic fiber only in the area facing the magnet on the mold side, without damaging the flexibility of the fiber material, and without substantially increasing the weight of the fiber material, Molding can be performed by firmly holding the fiber material on the inner surface of the mold by magnetic force.

  In addition, although a magnet is suitable as a magnetic body, an electromagnet may be sufficient.

  Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a sectional view for explaining a mold used in the method for producing a foamed resin molded product according to the embodiment, and FIG. 2 is an enlarged sectional view of the vicinity of the magnet in FIG. Since this mold is symmetrical, only the left half is shown in FIG. The right half appears symmetrically with the left half.

  The mold for foam molding used in this embodiment is for molding an automobile seat pad, and includes an upper mold 1 and a lower mold 2. The upper mold 1 and the lower mold 2 are each made of a nonmagnetic metal material such as aluminum or an aluminum alloy.

  A plurality of magnets 3 are provided on the inner surface of the upper mold 1, that is, the cavity surface. In this embodiment, a recess is provided in the inner surface of the upper mold 1, and the magnet 3 is fitted in this recess. The magnet 3 is fixed to the upper mold 1 by a fixing method such as caulking, screwing, bolting, and adhesion. The surface of the magnet 3 is flush with the surrounding upper mold cavity surface.

The area facing the cavity surface of one magnet 3 is preferably about 1 to 2000 mm ² . It is sufficient that about 5 to 50 magnets 3 are arranged per 1 m ² , but it may be more or less than that.

  Moreover, it is preferable to arrange the magnet 3 at a predetermined interval in the edge direction so that the edge does not turn over on the cavity surface where the edge of the sheet-like auxiliary material 4 faces.

  The auxiliary material 4 is in the form of a sheet, and in this embodiment is made of a fiber material. A magnetic thread 5 is sewed by a sewing machine or the like on a region of the auxiliary material 4 facing the magnet 3. The magnetic yarn 5 is magnetically attracted to the magnet 3 so that the sheet-like auxiliary material 4 is held in close contact with the inner surface of the upper mold 1 as a whole.

  In order to perform foam molding of the seat pad, after supplying the urethane stock solution into the lower mold 2, the upper mold 1 in which the auxiliary material 4 is magnetically attached to the inner surface as described above is attached to the lower mold 2. Tighten and heat foam urethane.

  After foaming, the mold is opened and the molded product is removed. The auxiliary material 4 is integrated with the foam molded product, and is smoothly separated from the upper mold 1.

  In the cavity center portion 6 shown in FIG. 1, seat portions such as the lower part of the bottom and the lower thigh of the seat pad are formed, and in the cavity side portion 7, the side portion (bank portion) of the seat pad is formed. The auxiliary material 4 is arranged on the bottom surface of the molded seat pad.

  As the magnetic yarn 5, a metal yarn such as iron or nickel is suitable because it is inexpensive and may be a magnetic yarn obtained by kneading a ferromagnetic metal oxide powder with a binder and extruding it into a yarn shape. Alternatively, a magnetic yarn having a core-sheath structure in which a ferromagnetic material is disposed in a hole of a synthetic resin hollow fiber may be used.

  The thickness of the magnetic thread 5 may be anything that can be sewn. However, if the thickness is excessively thin, the number of stitches increases, and if it is excessively thick, the follow-up to the cloth is poor. Therefore, about 100 to 500 μm is usually preferable.

  In the case where the auxiliary material 4 is a fiber material, examples of the fiber constituting the fiber material include, but are not limited to, a woven fabric or a nonwoven fabric of synthetic resin fibers such as polyester, acrylic, and polypropylene.

  The above embodiment is an example of the present invention, and the present invention may take forms other than those shown in the drawings. For example, the present invention can be applied to molding of a foam molded product other than a seat pad. In the case of a secondary material having a bag shape such as a back pad, it is necessary to sew in order to make the shape. However, by performing this sewing with a magnetic thread, both sewing and positioning (magnetization) can be performed.

  In the present invention, the resin is not limited to urethane. The auxiliary material may be a sponge other than the fiber material.

It is sectional drawing explaining the shaping | molding method which concerns on embodiment. It is an expanded sectional view of the magnet vicinity of FIG.

Explanation of symbols

1 Upper mold 2 Lower mold 3 Magnet 4 Secondary material 5 Magnetic yarn

Claims (6)

A method for producing a foamed resin molded product in which the subsidiary material is integrated by holding the subsidiary material on the inner surface of the mold and foaming the foamed resin stock solution in the mold,
In the method for producing a foamed resin molded article, in which magnetism is imparted to the auxiliary material, a magnetic body is installed in the mold, and the auxiliary material is held on the inner surface of the mold by the magnetic force of the magnetic body.
A method for producing a foamed resin molded product integrated with a secondary material, wherein the secondary material is magnetized by sewing a magnetic fiber to the secondary material.   2. The method for producing a foamed resin molded product according to claim 1, wherein the foamed resin is a urethane foam resin.   3. The method for producing a foamed resin molded product according to claim 1, wherein the magnetic fiber is a magnetic metal fiber.   4. The method for producing a foamed resin molded article according to claim 1, wherein a magnet is attached to the inner surface of the mold, and the magnetic fiber is magnetically attached to the magnet.   5. The method for producing a foamed resin molded product according to claim 4, wherein the magnetic fiber is sewn in a region of the auxiliary material facing the magnet.   6. The method for producing a foamed resin molded product according to claim 1, wherein the auxiliary material is made of a fiber-based material.

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