JPS61130012A - Method of molding multilayered cushion pad - Google Patents

Abstract

PURPOSE:To obviate mixing of compound liquids for molding a foamed body having different hardnesses to stabilize the product, by using one bottom force and a plurality of top forces thereby foam molding foamed bodies with different hardnesses successively in a layered manner. CONSTITUTION:The upper outer configuration of a cushion pad 10 is formed by a bottom force 1, then a top force 2 is placed on the bottom force 1, and a compound liquid for molding a foamed body having a rather soft hardness is injected, and is foamed to form a surface layer section foamed body 11 of the cushion pad 10. Then the first top force is removed, and with the bottom force 1 left, a second top force 3 is placed over the surface layer section foamed body 11. This second top force 3 constitutes the bottom surface outer configuration of the cushion pad, then a compound liquid for molding a rather hard section is injected and foamed between the surface layer section foamed body 11 and the top force 3 to form a deep layer section foamed body 12, which is integrated with the surface layer section foamed body 11 thereby forming the cushion pad 10.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for molding a cushion pad, which is formed by integrally forming a plurality of foams having different hardness in a layered manner.

(Prior art) For example, when the seat main part A is required to be soft and the main side part B is required to be hard, such as the cushion pad for a vehicle seat shown in FIG. 4, the cushion pad is formed. Usually, the following two methods are adopted.

One method is to integrally mold this pad, and as shown in Figure 5 (a), two types of foam molding solution with different hardness are used (arrow a in the figure indicates a softer hardness). ,b
The hardness of the hardness is injected almost simultaneously into the mold and molded, but with this method, the parts around the bifurcation point of both hardnesses mix, resulting in a lack of stability as a product. Therefore, clarifying the difference in hardness is largely influenced by the shape of the product.

Another method is to mold the foam b' of one hardness in advance, set it in the foam mold (X) of the other hardness, and then mold the foam b' of the other hardness, as shown in Figure 5 (b). It is molded by pouring a hard foam mixture a'.

When using this method, it is necessary to mold the foam of one hardness and then set it in the mold X of the other hardness, which not only increases the number of man-hours but also costs money in terms of equipment, etc. There is a problem in that it is high.

(Objective of the Invention) In view of these points, the present invention is capable of arbitrarily obtaining portions with different hardness differences without being affected by the product shape.
Furthermore, the aim is to provide a method for molding a multilayer cushion pad that has a simple manufacturing process and can reduce costs.
After forming a foam layer of a first hardness with the upper mold and removing the first upper mold, a second -1- mold is placed on top of the foam layer of the first hardness described in -1-. , inject a foam molding mixture having a second hardness between a foam layer having a first hardness and a second upper mold to form a foam layer having a second hardness, and forming a foam layer according to the number of layers. ``Sequentially'' - By repeating the same procedure as above by changing only the mold, a plurality of foams with different hardnesses are formed in layers.

(Example) Hereinafter, the present invention will be described in detail based on the illustrated example. FIGS. 1 and 2 show an embodiment in which a cushion pad for a vehicle seat is manufactured according to the present invention. First, in FIG. An out-of-plane shape is formed, and the upper mold 2 is placed on the lower mold 1 to soften it.

Next, as shown in FIG. 1(b), the first mold 2 is removed, and a second upper mold 3) is placed above the surface foam 11 using the lower mold 1 as it is. . This second mold 3 forms the outer shape of the bottom surface of the cushion pad 10,
A molding compound with a harder hardness is injected between the second upper mold 3 and the surface foam 11, and is foamed to form the deep foam 12 of the cushion pad IO. By integrating the foam 12 and the surface foam 11,
A cushion pad 1O shown in FIG. 3(a) is obtained.

In these two-stage foaming operations, when injecting each compounded liquid, the runner 4 is placed in the positional relationship shown in FIG. 2 with respect to the lower mold 1 and the upper molds 2 and 3. That is, first, in molding the surface foam 11, a liquid is injected into the internal space formed by the lower mold 1 and the first upper mold 2 from the path 5 in the figure shown in FIG. Meanwhile, the second stage foaming process is being carried out. In molding the deep layer foam 12, a liquid is injected from the path indicated by reference numeral 6 in FIG. 2 (b) and foamed under high pressure.

Also, as shown in FIGS. 2(c) and 2(d), the lower mold l.

On the other hand, a foam 11' is formed by injecting liquid from the gate 13 installed in the -L type 2'' [see Fig. 2 (c)], or the -F type 3 in the second stage is formed. Game set up in )1
There is also a method of high-pressure foaming by injecting liquid from step 4 [see Figure 2 (d)].

Therefore, the cushion pad obtained in this way is
Since the surface layer foam 11 is soft and the deep layer foam 12 is made of hard foam, it provides a soft feeling at the initial stage of sitting, and provides a feeling of support when fully seated, helping to stabilize the final posture. It can be held firmly.

In addition, according to this embodiment, a desired hard foam can be easily formed depending on the part of the pad, so chips and palms that were conventionally required inside the pad can be easily formed.

There is no need for a supporter such as felt, and unlike in the case of bonding, there is no restriction to the external shape of the product, and there is no step formed at the boundary between the two layers, and the impregnated layer in this area appears on the skin. It has the advantage of not being stored away.

The present invention is applicable not only to vehicle seat cushion pads but also to various cushion pads used for other purposes, and can also be applied to molding multilayer cushion pads such as three layers using the same procedure. Needless to say.

(Effects of the Invention) As described above, according to the present invention, one lower mold and a plurality of upper molds are used to perform foam molding in layers of foams having different hardnesses. The body molding liquids do not mix together, making it possible to stabilize the product.
In addition, a foam of desired hardness can be easily formed at a desired location regardless of the external shape of the product, and since multiple foaming steps are performed in the same manufacturing process, manufacturing costs can be kept low. It is possible.

[Brief explanation of drawings]

FIGS. 1(a) and (b) are cross-sectional explanatory diagrams showing an outline of the process according to an embodiment of the present invention, and FIGS. 2(a) and (b) are cross-sectional explanatory diagrams showing the positions of the runners in FIG. 1. , $3 figure (a)
(B) is an external view and cross-sectional view of a vehicle seat cushion pad molded by the process shown in Figure 1. Figure 4 is an external view of a vehicle seat to explain the conventional method.
B) are both schematic explanatory diagrams of steps related to the conventional method.
In the figure, 1 is a lower mold, 2 is a first upper mold, 3 is a second upper mold, 4 is a runner, 5 and 6 are paths, 10 is a cushion pad, 1
1 is a surface layer foam, and 12 is a deep layer foam. Figure 1 ゛(a)(b)
Figure 2 Figure 3 C (A) Figure 5 (B) Procedural amendment (method) % formula % 2. Name of the invention Method for molding a multilayer cushion band 3. Relationship with the person making the amendment Name of patent applicant Ikeda Bussan Co., Ltd. Representative: Ike 1) Hisashi 4, Agent address: 4th floor, Hanakiku Building, 3-22-4 Uchikanda, Chiyoda-ku, Tokyo Telephone: 03-256-1747 March 26, 1985 (Delivery date) 6 , subject of amendment 4, brief explanation of the drawings) 7. In the description of the contents of the amendment, page 7, line 11, "Cross-sectional explanatory drawing, Figures 3 (a) (b)...・・・”
It says, ``Explanatory cross-sectional diagrams, Figures 2 (C) and (D) are explanatory cross-sectional diagrams showing different embodiments of the present invention, and Figures 3 (A) and (B)...
"..." I corrected myself. that's all

Claims (1)

[Claims] A foam layer of a first hardness is formed by the lower mold and the first upper mold, and after removing the first upper mold, a second upper mold is placed on top of the foam layer of the first hardness. , inject a foam molding mixture having a second hardness between a foam layer having a first hardness and a second upper mold to form a foam layer having a second hardness, and forming a foam layer according to the number of layers. A method for molding a multilayer cushion pad, in which a plurality of foams with different hardnesses are integrally formed into layers by sequentially replacing only the upper mold and repeating the same steps as above.