JPS60127116A - Manufacture of integrally foam-molded product - Google Patents

Abstract

PURPOSE:To integrally mold cushioning body without impairing air permeability by a method wherein the cushioning body is integrally foam-molded onto the surface on the side of a high density layer formed on the side opposite to a side, onto which an open cell sheet joined on the back of a skin material is joined. CONSTITUTION:A high density layer 4 is formed by plastically deforming the one face of an open cell sheet 3, the other face of which is joined onto the back side of a skin material 1. In order to manufacture a cushioning body 2 integral with the skin material 1 by means of foaming resin, foaming resin is poured onto the inner surface side of the high density layer 4 so as to foam under low pressure. The external appearance of the skin material 1 of the integrally foam- molded product obtained in the above-mentioned method is free from being marred, because the foaming resin does not soak through the high density layer 4 outwards. In addition, because some foaming resin permeate into and harden the surface layer side of the high density layer 4, the cushioning body 2 and the open cell sheet 3 are made into an integral body and, together with the air permeability held by the open cell sheet 3, a soft product with favorable cushioning property and excellent surface feeling is realized.

Description

DETAILED DESCRIPTION OF THE INVENTION Technical Field The present invention relates to a method of manufacturing an integrally foamed molded article, in which a kungjong body is integrally molded with a foamed resin using a fabric such as a woven or knitted fabric as a skin material.

Background technology: Conventionally, for example, when manufacturing a headrest tray or seat, a fabric such as a woven or knitted fabric is used as the skin material, and foamed resin is used as the skin material.When integrally molding the cushion body, the skin of the foamed resin is To prevent seepage or impregnation of! Film or closed cell (non-breathable) on the back of the i fabric
The cushion body is integrated with the skin material by laminating elastic sheets, molding the multilayer material into a desired three-dimensional shape, and then injecting urethane stock solution into the mold and foaming it. . However, in integral foam molded products such as head restraints, the film laminated to the back of the fabric and the closed-cell elastic sheet are non-breathable materials, so breathability is impaired, resulting in lack of flexibility and surface texture. There are disadvantages that are inferior to.

DISCLOSURE OF THE INVENTION An object of the present invention is to provide a method for manufacturing an integrally foamed molded product that can integrally mold a cushion body without penetrating foamed resin into fabrics such as woven or knitted fabrics and without impairing breathability. .

That is, in the method for manufacturing an integrally foamed molded article according to the present invention, an open-cell sheet that is thermally plastically deformed is bonded to the back side of a skin material made of fabric such as woven or knitted fabric, and other than the bonded sheet is bonded. The air bubbles are compressed into a high-density layer by thermally plastically deforming the surface side, and the cushion body is integrally foam-molded with foamed resin on the high-density layer side.

Example The following description will be made with reference to the drawings.

This method uses 41 pieces of woven or knitted fabric as one skin material.
By using a base material and integrally molding the cushion body 2 with a foamed resin such as a urethane solution on the back side thereof, it can be applied to manufacturing hentrest restraints and other objects having three-dimensional shapes.

First, the open-cell sheet 3 is bonded to the back side of the skin material 1. As the sheet 3, a resin sheet such as a soft urethane sheet or a polyvinyl chloride foam sheet, which can be thermally plastically deformed, can be used and bonded to the back surface of the skin material 1 with an adhesive. Next, the multilayer material is subjected to heat treatment to plastically deform one side of the open-cell sheet 3. When manufacturing a molded product that has to be molded into a three-dimensional shape, the heat treatment is carried out using a concave thermo mold l"M and a presser die P (see Fig. 2), or by pressing in split molds m1 and m2. ,
<-Means for expanding the bank B (see FIG. 3) can be applied. In these means, the open-cell sheet 3 is heated by heating the thermomold M or the split molds m1 and m2.
By pressing the other bonded surface side to each mold surface, the multilayer material can be molded into a three-dimensional shape and at the same time heat treatment can be applied to one side of the open-cell sheet 3. Further, these means are preferable because they do not crush the nap of the woven or knitted fabric used as the skin material 1. On the other hand, open-cell sheets 3
By applying a pinch roll with a hot roll on the side in contact with the material, it is possible to plastically deform a portion in the thickness direction while compressing with the roll. Further, a hot iron can also be used in cases where it is sufficient to apply heat treatment to a narrow area. In this heat treatment, a high-density layer 4 is formed on one side of the open-cell sheet 3 by plastic deformation.
The high-density layer 4 maintains a certain degree of air permeability by compressing the air bubbles, but can be formed as a dense layer that does not ooze out foamed resin such as urethane stock solution, which will be described later. . This high-density layer 4 is positioned on the inner surface side when the multilayer material is molded into a three-dimensional shape. For example, in the case of heat treatment using a thermo mold M and a presser mold P, the multilayer material is placed in the foam molds F'm3 and In4 with the side in contact with the thermo mold M being the inner surface, and the rubber puncture B is used to In the case of expansion molding, it may be inverted so that the skin material 1 is on the front side and housed in the foam mold. In addition to these, even when the multilayer material is made into a three-dimensional shape by vacuum forming, high frequency weltering, ultrasonic weltering, or sewing machine, the high density layer 4 is formed so as to be located on the inner surface side. By injecting a foamed resin such as a urethane stock solution into the inner surface and foaming at low pressure, it is possible to manufacture a head restraint or the like in which the foamed resin cushion body 2 and the skin material 1 are integrated.

In the integrally foamed molded product obtained in this way, the foamed resin does not ooze out beyond the high-density layer 4, so the appearance of the skin material 1 is not impaired, and there is some foaming on the surface side of the high-density layer 4. Since the resin permeates and hardens, the cushion body 2 and the open-cell sheet 3 become integrated, and since the open-cell sheet 3 maintains air permeability, it is flexible and has good cushioning properties, as well as a surface texture. It becomes an excellent product.

In the above embodiment, the high-density layer 4 was formed after the skin material 1 and the open-cell sheet 3 were bonded, but it may be provided in advance before the open-cell sheet 3 is bonded. Furthermore, when manufacturing a head restraint, etc. during foam molding of the shoe body 2, the stays and core metal can be inserted into the foamed resin and attached integrally.

Effects of the Invention As shown in E-E, according to the method for manufacturing an integrally foamed molded product according to the present invention, even when fabrics such as woven or knitted fabrics are used as the skin material, the foamed resin does not ooze out and the appearance is not impaired. In addition, it is possible to produce a product with a good appearance due to the texture of the fabric, and it is also possible to obtain a product with extremely good cushioning properties because it maintains air permeability.

[Brief explanation of the drawing]

FIG. 1 is a partially enlarged side sectional view of an integrally foamed molded article obtained by the method according to the present invention, and FIGS. 2 to 4 are explanatory views showing the manufacturing process of the integrally foamed molded article according to the present invention. skin material, 2: cushion body, 3: open cell sheet,
4: High density layer.

Claims (1)

[Claims] A fabric made of woven or knitted fabric as the skin material, an open-cell sheet that is thermally deformed plastically bonded to the back side, and the other side of the bonded sheet is thermally plastically deformed to compress the air bubbles. 1. A method for manufacturing an integrally foamed molded product, characterized in that a cushion body is formed on a dense layer, and a cushion body is integrally molded with a foamed resin on the side of the high-density layer.