JP4116012B2 - Manufacturing method of seat pad - Google Patents

Description

  The present invention relates to a method of manufacturing a cushion pad (seat pad) for use in a vehicle, particularly an automobile seat.

  As a vehicle seat cushion pad (seat pad) used for a vehicle seat, usually molded flexible polyurethane foam is used. The sheet pad made of such flexible polyurethane foam uses a molding die consisting of an upper die and a lower die that can be opened and closed by a hinge or a cylinder, and generally the lower die with the die open. To supply a foamed stock solution composition that forms a flexible polyurethane foam to the mold, close the mold, and foam and cure the foamed stock solution composition in a molding cavity formed by an upper mold and a lower mold to form a sheet pad Is well known.

  In the manufacture of the above seat pad, insert metal fittings or hook-and-loop fasteners for mounting the seat material of the seat, increasing the strength on the back side of the pad, or when the seat pad is mounted on the vehicle and traveled A flexible polyurethane foam is applied to the molding cavity with a non-woven fabric molding base fabric cut out in a predetermined shape for the purpose of preventing abnormal noise generated by sliding with frame metal fittings and springs. A technique for supplying a foaming stock solution composition to be formed, foaming and curing in a molding die, and integrating these members is known (for example, Non-Patent Document 1).

Keiji Iwata, "Polyurethane resin handbook" (Nikkan Kogyo Shimbun, 1987), page 177

  In the sheet pad manufacturing method disclosed in Non-Patent Document 1 or the like, the molded base fabric is cut into a predetermined shape in consideration of the shape of the sheet pad to be molded in advance, and partially sewn as necessary. After performing the above, the foaming stock solution composition is supplied and molding is carried out after mounting on the upper mold of the molding die that mainly forms the back surface of the sheet pad. In such a manufacturing method, the molding base cloth can be attached to the molding die with the molding base cloth as it is on the locking pin provided on the mold, or on the molding base cloth if necessary. This is performed by piercing into a locking hole formed in accordance with the position of the above, or by locking the bag-shaped part formed by sewing as described above to the convex part formed in the mold.

  In recent years, as the quality of vehicles has improved, the shape of the seat pad has become complicated, and products having a thin folded portion on the back side of the seat at the peripheral edge have been demanded as a seat pad for a backrest, for example. Yes. As described above, the molded base fabric increases the strength on the back side of the seat pad and prevents abnormal noise caused by sliding with the frame metal fittings and springs when the seat pad is mounted on the vehicle. This is an object, and in the thin folded portion at the end, a laminated base fabric is particularly required for improving the strength.

  However, the part of the molding die that forms the thin folded portion at the end of the pad for the sheet is a narrow cavity, and it is difficult to stand the locking pin in terms of mold processing, and the small locking pin is set up. Even so, it is difficult to pierce and mount the base fabric in the manufacturing process of the sheet pad.

  Also, in order to allow the operator to attach the molding base fabric by erecting the locking pin, the upper mold faces the lower mold, the outer mold that forms the parting part, and the molding cavity. It is divided into an inner mold that forms a part, and the inner mold recedes to the outer mold side to form a thin molded part that forms a thin folded portion between the inner mold and the outer mold. It is possible to configure so that the space between the thin-walled molding portions is widened so that the operator can enter the space between the advancing positions where the advancing and separating positions are separated.

  However, even when the upper mold is divided into the outer mold and the inner mold as described above, the end of the molding base fabric is locked and the thin molded portion of the inner mold to be mounted is viewed from the operator as the inner mold. Since it is not visible from the operator's position on the back side, it is necessary to look for the position of the locking pin with a hand, and there is a mistake in mounting the molding base fabric on the molding line where the mold moves continuously, An operator may injure a fingertip, and improvement is required.

  The present invention provides a sheet pad that can easily and safely manufacture a sheet pad having a thin folded portion on the back surface side at the peripheral edge, and a molded base fabric laminated on the folded portion. It aims to provide a method.

The sheet pad manufacturing method of the present invention is configured to be openable and closable, and a molding base fabric is attached to a molding surface of the upper mold of a molding die having an upper mold and a lower mold that are formed in a closed state. A secondary material mounting step, a foaming stock composition for forming a flexible polyurethane foam in a state where the molding die is opened or closed in the molding cavity, and foamed and cured to form a sheet pad And a demolding step of opening the molding die and taking out the sheet pad,
The sheet pad has a thin folded portion in which the molded base fabric is laminated at an end portion,
The upper mold includes an outer mold that forms the parting portion with the lower mold, and an inner mold that faces the molding cavity and forms a part of the molding surface, and the inner mold is on the outer mold side. And is configured to be freely retractable between a retracted position where the thin folded portion is formed between the inner mold and the outer mold and an advanced position where the outer mold is advanced and separated from the outer mold side,
A surface fastener male member is provided on the molding surface of the thin folded portion of the inner mold .

  With the manufacturing method having such a configuration, it is possible to easily and safely manufacture a pad for a sheet having a thin folded portion on the back surface side at the peripheral edge portion and a molded base fabric laminated on the folded portion. That is, the hook-and-loop fastener male member is lower in height from the mold surface than the locking pin, and can easily lock the nonwoven fabric constituting the molded base fabric. In addition, since the locking member is flexible, it is not injured like a metal locking pin even if an operator touches it with a hand.

  With the manufacturing method having such a configuration, even if the peripheral edge portion has a thin folded portion on the back side, and the wall thickness of the folded portion is thin or the shape is complicated, a molded base fabric is laminated on the folded portion. It is possible to easily and safely manufacture the seat pad.

  As the surface fastener male member used in the present invention, a known surface fastener male member can be used, and a surface fastener having a resin J-shaped, mushroom-shaped or the like erected on a base fabric. A male member is illustrated.

  In the manufacture of the seat pad, as an auxiliary material other than the molded base fabric, an insert fitting for attaching and fixing the seat pad coated with the skin material to the metal fitting, and a surface for covering and fixing the skin material to the seat pad A rigid foam block or the like for partially forming a high-hardness portion on the fastener or sheet pad is used as necessary.

  FIG. 1 is a perspective view illustrating a state where a molding base fabric is mounted on a molding die. The seat pad to be manufactured constitutes the back portion of the seat. The molding die 10 is composed of an upper die 12 and a lower die 16, and the upper die 12 has a base portion 21, and is mounted and fixed to the switchgear upper member 18 by the base portion 21. The lower mold 16 is mounted and fixed to the opening / closing device lower member 20. The opening / closing device upper member 18 is configured to be opened and closed by a hydraulic cylinder 22. That is, the molding die 10 is configured to be opened and closed by the hydraulic cylinder 22 connected to the opening / closing device upper member 18. When the molding die 10 is opened and closed, the molding die may be provided with a hinge, and as shown in FIG. 1, an opening / closing device upper member 18 for fixing the upper die 12 and the lower die 16 and the opening / closing device. The lower member 20 may be freely opened and closed by a hinge.

  Since the worker who mounts the auxiliary material works while standing on the left side of FIG. 1 (the position facing the molding surface of the opened upper mold), the lower surface of the lower end of the inner mold 14 cannot be seen. According to the present invention, when the lower end portion of the molded base fabric is attached to the lower surface of the lower end portion of the inner mold 14 as described above, the tip is made of metal as in the prior art in order to be engaged with the male member of the hook-and-loop fastener. An operator is not injured compared with the case of using a sharp locking pin.

  In the example shown in FIG. 1, the upper mold 12 is composed of an inner mold 14 and an outer mold 12a, and the inner mold 14 is formed in the molding cavity formed when the molding die is closed from the outer mold 12a, that is, the outer mold 12a. The sheet pad is formed at a position separated from the mold 12a and retracted from the outer mold 12a and moved away from the outer mold 12a. It is configured to facilitate operations such as cleaning the mold and mounting the molding base fabric.

  FIG. 2 is a cross-sectional view showing the XX cross section of FIG. 1 of the upper mold 12 attached and fixed to the opening / closing device upper member 18. The upper mold 12 is composed of an inner mold 14 and an outer mold 12a. The inner mold 14 is fixed to a rod 26 of an air cylinder 28 provided outside the outer mold 12a. It is configured such that it can be moved back and forth between an advancing position separated from 12a and advanced toward the molding cavity and a retracted position retracted toward the outer mold 12a to form a molding surface of a predetermined upper mold 12. A molding base fabric 24 is attached to the inner mold 14. The molding base fabric 24 is attached at the advanced position of the inner mold 14, and then retracted to the retracted position to prepare for molding. The molded base fabric 24 is formed in a bag shape by sewing and locked to the upper part of the inner mold 14 and the lower part is a free end and faces the back of the inner mold 14, that is, the outer mold 12a. The male member 34 of the hook-and-loop fastener disposed at the end position of the thin folded portion forming surface 32 that forms the thin folded portion of the seat pad is latched and attached.

  In the state in which the molding die is opened, other auxiliary materials such as the molding base fabric 24 and the insert fitting are mounted as described above (submaterial mounting step). After the auxiliary material mounting process is completed, the inner die 14 is retracted to the retracted position on the outer die 12a side by the action of the air cylinder 28, and the thin folded portion is formed by the thin folded portion molding surface 32 and the outer folded thin folded portion molding surface 33. A molding cavity for molding is formed.

  FIG. 3 is a perspective view showing the lower end portion of the surface constituting the molding cavity that faces the back of the inner die 14, that is, the outer die 12 a and forms the thin folded portion of the sheet pad. A male member 34 of a hook-and-loop fastener is fixed to the inner mold 14 that forms the end of the thin folded portion. The surface fastener male member 34 can be fixed to the inner mold 14 by direct fixing using an adhesive, direct screwing, a method of fixing the male member to a metal plate by adhesive bonding or caulking and then screwing. The lower free end of the molded base fabric 24 is folded back and locked to the surface fastener male member 34 of the inner mold 14 to complete the mounting of the molded base fabric. In FIG. 3, two strip fastener male members 34 are disposed in a strip shape, but may be a continuous ribbon shape or may be disposed on the entire thin folded portion forming surface 32.

  In FIG. 4, after the inner mold 14 fitted with the molding base fabric 24 is retracted to the retracted position, the upper mold 12 is moved by the hydraulic cylinder and is brought into contact with the lower mold 16 to be closed, thereby forming a molding pad for a sheet pad having a predetermined shape. The state where the tee 30 is formed is shown. Generally, before the mold 10 is closed, the foamed stock solution composition is supplied to the concave portion of the lower mold 16 and foamed and cured to form a sheet pad (foaming step). The foaming stock composition may be supplied from an injection hole provided in the upper mold 12 after the molding die 10 is closed. Following the foaming step, the molding die 12 is opened, the inner die 14 is advanced to the advanced position, and the sheet pad is removed (demolding step).

  FIG. 5 is a perspective view illustrating a sheet pad 40 having a thin folded portion, and FIG. 6 is a YY sectional view of FIG. The illustrated seat pad 40 is a backrest cushion material of the seat, has a backrest 42 and a thin folded portion 42E at the lower end, and is an inner surface of a back concave portion formed by the inner mold 14 of the molding die 12. The molded base fabric 24 is laminated on the inner surface of the end portion of the thin folded portion 42E.

A perspective view illustrating a state in which a molding base fabric is mounted on a molding die Sectional drawing which showed the XX cross section of FIG. 1 of the upper type | mold mounted and fixed to the switchgear upper member The perspective view which showed the lower end part of the surface which comprises the shaping | molding cavity which forms the thin wall folding | turning part of the pad for sheets Sectional drawing which showed the state which formed the molding cavity of the pad for sheet | seats of a predetermined shape, after the inner mold | type which mounted the molding base fabric retracted to the retreat position, closed the molding die The perspective view which illustrated the pad for sheets which has a thin folded part YY sectional view of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Molding die 12 Upper mold | type 24 Molding base fabric 30 Molding cavity 34 Surface fastener male member

Claims (1)

A sub-material mounting step for mounting a molding base fabric on the molding surface of the upper mold of a molding die having an upper mold and a lower mold that are configured to be openable and closable, and to form the molding cavity in a closed state. Supplying a foaming stock solution composition for forming a flexible polyurethane foam in a state where the molding die is opened or in a state where the mold is closed, and foaming and curing to form a pad for a sheet, and opening the molding die to Having a demolding step of taking out the pad for the sheet
The sheet pad has a thin folded portion in which the molded base fabric is laminated at an end portion,
The upper mold includes an outer mold that forms the parting portion with the lower mold, and an inner mold that faces the molding cavity and forms a part of the molding surface, and the inner mold is on the outer mold side. And is configured to be freely retractable between a retracted position where the thin folded portion is formed between the inner mold and the outer mold and an advanced position where the outer mold is advanced and separated from the outer mold side,
A method for producing a pad for a sheet, wherein a surface fastener male member is disposed on the molding surface of the thin folded portion of the inner mold .

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