JP2000190340A - Production of integral-skin foam molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To avoid generation of a product of inferior quality wherein the inner part is opened from a slit-shaped opening part as an integral-skin foam molded article by surely sticking spaces for sealing folded inward from the slit-shaped opening part and facing each other. SOLUTION: An inserting hole 12 for a resin injection nozzle N is provided on the skin face by closely positioning it to either one of spaces 10a and 10b for sealing facing each other inside of the skin 1 and a foaming resin is filled inside of the skin from the apex of the resin injection nozzle N inserted inward from the inserting hole 12 of this skin 1 while the resin is brought into direct contact with the spaces 10a and 10b for sealing and they are impregnated with the resin and a cushioning layer is foam-molded from the foaming resin. In addition, facing spaces 10a and 10b for sealing are stuck each other with the impregnating resin.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a foam-integral skin molded article which is applied to produce a headrest or the like for a seat as a foam-integral foam molded article.

[0002]

2. Description of the Related Art Conventionally, when a headrest of a vehicle seat is manufactured as a foam-molded product integrally formed with a skin, a headrest frame integrated with a headrest stay is sewn into a hollow three-dimensional shape (hereinafter referred to as a "headrest cover"). ), It is necessary to fold the opposing sealing margins inside and use a headrest cover having a horizontally elongated slit-shaped opening provided on the bottom surface in the width direction.

The slit-shaped opening of the resin injection nozzle for forming a cushion layer (hereinafter referred to as "cushion pad") is formed by inserting a resin injection nozzle into the headrest cover and filling the foamed resin. It is also used as an insertion slot.

However, if the headrest is foamed as a cushion pad after filling with foamed resin, the foamed resin moves to the sealing allowance at the end of foaming, so that the opposing sealing allowance is sufficiently pressed and fixed with the cushion pad. Since it cannot be performed, a defective product in which the slit-shaped opening is easily opened and the inside is visible tends to occur.

[0005]

SUMMARY OF THE INVENTION The present invention does not allow the inside to be opened from the slit-shaped opening as a skin-integrated foam molded product by folding the interior through the slit-shaped opening and securely bonding the opposing sealing margin. It is an object of the present invention to provide a method for producing a skin-integrated foam molded article that can be produced without producing non-defective products.

[0006]

In the method for producing a skin-integrated foam molded product according to the present invention, a hollow three-dimensional skin having a slit-shaped opening provided in a width direction by folding an opposing sealing margin inward. In order to fill the inside of the skin with a foamed resin with a resin injection nozzle and foam the cushion layer integrally, the insertion opening of the resin injection nozzle is sealed with one of the sealing allowances facing the inside of the skin. It is provided on the surface of the skin so that it is located close to the surface, and the inside of the skin is filled while the foaming resin is directly applied to the sealing allowance and impregnated from the tip of the resin injection nozzle inserted into the inside of the skin from the insertion opening, and the cushion layer is formed from the foaming resin. Are foamed, and the opposing sealing margins are adhered to each other by an impregnating resin.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the accompanying drawings, the illustrated embodiment is applied to manufacture a headrest of a vehicle seat as an integral foam molded article on a skin. This headrest is provided with a headrest cover 1 sewn in a hollow three-dimensional shape as a skin as shown in FIG.
The headrest frame 3 integrally assembled with the headrest stay 2 is assembled inside, and the cushion pad 4 is integrally formed as a cushion layer by foam molding.

The headrest cover 1 is made of a wadding material 1 such as a skin material 1a such as fabric, synthetic leather, or real leather.
A laminated material backed by b can be used. The headrest cover 1 is sewn in a hollow three-dimensional shape, and since the headrest frame 3 assembled integrally with the headrest stay 2 needs to be assembled inside, the opposing sealing margins 10a and 10b are folded inward to form the headrest cover 1. An elongated slit-shaped opening 11 extending in the width direction is provided on the bottom surface.

The slit-shaped opening 11 is used for assembling the headrest frame 3, and an insertion port 12 for a resin injection nozzle is separately provided. The insertion port 12 of the resin injection nozzle is an opening having a diameter into which the nozzle tip of the resin injection nozzle can be inserted, and is formed inside the headrest cover 1 so as to be located close to one of the opposing sealing margins 10a and 10b. The resin is provided at a distance where the resin can be directly sprayed onto the sealing margins 10a and 10b.

After assembling the headrest frame 3 inside the headrest cover 1, the headrest stay 2 is protruded out of the mold and inserted into the mold M as shown in FIG. In the molding die M, the resin injection nozzle N is inserted into the die through the insertion opening C of the die, and the tip of the nozzle is inserted through the insertion opening 12 of the headrest cover 1 as shown in FIG. The inside of the headrest cover 1 is filled so as to directly contact the sealing margins 10a and 10b from the tip of N.

[0011] The resin injection nozzle N is provided with a discharge port F of a foamed resin in a lateral direction near the tip of the nozzle.
The foamed resin can be efficiently applied directly to the sealing margins 10a and 10b. Further, since this foamed resin is directly applied to the sealing margins 10a and 10b, the impregnated resin E is generated in the sealing margins 10a and 10b as shown in FIG.

When the required amount of the foamed resin is filled into the headrest cover 1 and then foamed, the foamed resin swells inside the headrest cover 1 and the sealing allowances 10a and 1 are increased.
0b and, as shown in FIG.
cushion pad 4 so that a and 10b are pressed from both sides.
Are integrally foamed. When the cushion pad 4 is formed by foaming, the sealing margins 10a and 10b can be firmly bonded to each other by curing the impregnated resin E. For this reason,
It is possible to reliably prevent a defective product in which the interior of the cushion pad 4 can be seen from the outside due to the interior opening from the slit-shaped opening 11 as a headrest.

In the above-described embodiment, the case where one insertion port 12 for the resin injection nozzle is provided on the skin surface has been exemplified.
A plurality of foamed resins can be provided at a plurality of locations of the sealing margins 10a and 10b so as to be filled. The insertion port 12 of the resin injection nozzle is
As shown by 5, the cap 5 can be finally sealed by being fitted and fixed.

Further, in the above-described embodiment, the headrest is described as a foam-integral foam molded product. However, a hollow solid body in which the sealing margins 10a and 10b are folded inward to provide slit-shaped openings 11 in the width direction. The present invention can be widely applied to ones having a cushion-shaped skin integrally formed by forming a cushion layer.

[0015]

As described above, according to the method for producing a skin-integrated foam molded product according to the present invention, the insertion opening of the resin injection nozzle is positioned close to one of the sealing margins facing the inside of the skin. It is provided on the skin surface, and the foam resin is directly applied to the sealing allowance from the tip of the resin injection nozzle that is inserted into the inside of the skin through the insertion port of the skin, and filled into the skin while impregnating, and the cushion layer is foamed from the foam resin. In addition to molding, the opposing sealing margins are adhered to each other by impregnating resin, so as to ensure that the inside is opened from the slit-shaped opening as a skin-integrated foam molded product, and that the cushion layer becomes a defective product that can be seen from the outside. Can be prevented.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a headrest cover to which a method for producing a skin-integrated foam molded product according to the present invention is applied.

FIG. 2 is an explanatory diagram showing a molding die to which the method for producing the skin-integrated foam molded article is applied.

FIG. 3 is an explanatory view showing a filling step of a foamed resin to which the method for producing the skin-integrated foam molded article is applied.

FIG. 4 is an explanatory view showing a skin state after resin injection to which the method for manufacturing a skin-integrated foam molded article is applied.

FIG. 5 is an explanatory diagram showing a skin state after foam molding to which the method for manufacturing the skin-integrated foam molded article is applied.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Skin 10a, 10b Sealing margin 11 Slit-shaped opening 12 Nozzle insertion port N Resin injection nozzle

Continued on the front page F term (reference) 4F204 AA00 AD08 AG03 AG20 AH26 EA01 EB01 EB13 EF01 EF05 EF27 EL24

Claims (1)

[Claims] 1. A hollow three-dimensional skin in which opposed sealing margins are folded inward to form slit-shaped openings in a lateral width direction, and the inside of the skin is filled with a foamed resin by a resin injection nozzle. A method for producing a skin-integrated foam molded article in which a cushion layer is integrally foam-molded, wherein an insertion port of a resin injection nozzle is provided on a skin surface so as to be positioned close to one of opposing sealing margins inside the skin. The foaming resin is directly applied to the sealing allowance from the tip of the resin injection nozzle to be inserted into the inside from the insertion opening, and the inside of the skin is filled while being impregnated, and the cushion layer is foam-molded from the foaming resin, and the opposing sealing allowance is provided. Characterized in that they are adhered to each other by an impregnating resin.