JP2014097631A - Skin integration foam molding article and production method of the same - Google Patents

Abstract

An object of the present invention is to provide a skin-integrated foam-molded product capable of suppressing floating of the silver surface and a method for producing the same.
[Solution]
The headrest 10 according to the present invention is obtained by sewing a skin material 20 in which a backing material 22 is bonded to a genuine leather 21 into a bag shape, and foam-molding the core portion 15 inside the skin material 20. Here, the lining material 22 is subjected to corona treatment only on the surface of the genuine leather 21, and the core portion 15 is not fixed to the lining material 22. When a load F in a direction deviating from the backing material 22 is applied to the leather 21, the backing material 22 is in sliding contact with the core portion 15 so as to release the load F, so the load F is concentrated on the leather 21. This eliminates the need to lift the silver surface.
[Selection] Figure 4

Description

  The present invention relates to a skin-integrated foam-molded product obtained by sewing a skin material into a bag shape and foam-molding a core portion inside the skin material, and a manufacturing method thereof.

  Conventionally, products such as seat cushions and headrests that are covered with a skin material in which the foamed resin core is sewn in a bag shape are covered with the skin after the core has been foam-molded. It was manufactured by. However, this manufacturing method has a problem that it takes time and effort to cover the core material with the skin material. As a solution to this problem, so-called skin-integrated foam molding is known in which a core is integrally molded with a skin material by foaming a resin inside a skin material sewn in a bag shape (for example, Patent Documents). 1).

Japanese Patent No. 3307073 (paragraphs [0014], [0015], FIGS. 6 and 7)

  However, in the conventional skin-integrated foam molding described above, the core portion is fixed to the skin material. Therefore, when the leather is bonded with a lining material, the leather is affected by the environment and stretches. When a load that is raised and deviated from the backing material is applied, the load is concentrated on the leather, and there is a problem of so-called silver surface floating, in which a fluffy concave portion is generated on the surface of the leather.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a skin-integrated foam-molded product that can suppress floating of the silver surface and a method for producing the same.

  The skin-integrated foam-molded article according to the invention of claim 1 made to achieve the above object is obtained by sewing a skin material in which a backing material is bonded to leather into a bag shape, and forming a core inside the bag-shaped skin material. The surface integrated foam molded product formed by foaming the part has a feature in that the backing material can be slidably contacted with the core part.

  The invention according to claim 2 is characterized in that in the skin-integrated foam-molded article according to claim 1, the backing material is made of a foamed polyolefin resin, and the corona treatment is performed only on the bonding surface with the leather.

  The invention of claim 3 is characterized in that, in the skin-integrated foam-molded article of claim 2, the foamed polyolefin resin is a foamed polyethylene resin.

  According to a fourth aspect of the present invention, in the skin-integrated foam-molded article according to the first aspect, the backing material has a structure in which a resin film is bonded to the surface of the foamed resin sheet on the core side, and the core of the resin film It is characterized by applying a release agent to the surface on the part side.

  According to a fifth aspect of the present invention, there is provided a method for producing a skin-integrated foam-molded article, wherein a skin material obtained by bonding a backing material to leather is sewn into a bag shape, and a core portion is foam-molded inside the bag-shaped skin material. In the production method of the integral foam molded article, the backing material is made of a foamed polyolefin resin, and the corona treatment is performed only on the bonding surface with the leather, and after the core part is foam molded, crushing is performed, Or, it has a feature in that air is blown between the backing material and the core portion.

[Invention of Claim 1]
In the invention according to claim 1, in the case of the skin-integrated foam-molded product, when a load is applied to the leather in a direction deviating from the backing material, the backing material slides against the core portion so as to release the load. No longer concentrate, and can suppress the floating of the silver surface.

[Inventions of Claims 2 and 3]
In the invention of claim 2, the backing material made of foamed polyolefin resin is subjected to corona treatment only on the bonding surface with the leather, and therefore the backing material does not adhere to the core portion. Thereby, a lining material can be slidably contacted with respect to a core part, and a silver surface float can be suppressed.

  Here, examples of the foamed polyolefin resin include a foamed polyethylene resin and a foamed polypropylene resin, and a foamed polyethylene resin is preferred from the viewpoint of flexibility (the invention of claim 3).

[Invention of claim 4]
In the invention of claim 4, the backing material has a structure in which a resin film is bonded to the core portion side surface of the foamed resin sheet, and the release material is applied to the core portion side surface of the resin film. Therefore, the lining material does not adhere to the core portion. Thereby, a lining material can be slidably contacted with respect to a core part, and a silver surface float can be suppressed.

[Invention of claim 5]
In the invention of claim 5, since the backing material made of foamed polyolefin resin is subjected to corona treatment only on the bonding surface with the leather, the backing material does not adhere to the core portion. As a result, the backing material can be slidably contacted with the core portion, and the silver surface can be prevented from floating. Moreover, in the present invention, after foaming the core portion, crushing is performed, or air is blown between the backing material and the core portion, so that a gap is once formed between the backing material and the core portion. Thus, the backing material can be easily brought into sliding contact with the core portion.

The perspective view of the headrest which concerns on 1st Embodiment of this invention. Cross section of headrest Cross section around the skin material (A) Side sectional view around the skin material when a load is applied to the genuine leather, (B) Side sectional view around the skin material when the backing material is in sliding contact with the core portion Side cross-sectional view of skin material when foam resin material is injected Side cross-sectional view of skin material and core after foam molding Side cross-sectional view around the skin when blowing air Sectional drawing around the skin material of the headrest according to the second embodiment

[First Embodiment]
Hereinafter, a first embodiment in which the present invention is applied to a headrest of a vehicle seat will be described with reference to FIGS. As shown in FIG. 1, the headrest 10 includes a top portion of a gate-shaped stay 12 inside a headrest body 10H that has a substantially trapezoidal shape and is flattened back and forth. It extends side by side from the bottom of 10H. The legs 12 </ b> A and 12 </ b> A of the stay 12 are fixed to the upper part of the vehicle seat 90.

  As shown in FIG. 2, the headrest main body 10 </ b> H has a structure in which the outer side of the core portion 15 made of urethane foam resin is covered with a skin material 20 sewn in a bag shape. As will be described in detail later, the core portion 15 is obtained by foaming a foamed urethane raw material 35 (see FIG. 5) inside a bag-shaped skin material 20 set in a foam molding die 30.

  The stay 12 is set in the foam molding die 30 with the top portion inserted through the skin material 20 (see FIG. 5), and the core portion 15 is foam-molded so that the top portion of the stay 12 is the core portion 15. Buried inside.

  As shown in FIG. 3, the skin material 20 has a structure in which a backing material 22 is bonded to a genuine leather 21 (corresponding to “leather” of the present invention) so that the genuine leather 21 faces outward. It is sewn into a bag shape. The backing material 22 is a foamed polyethylene resin sheet 24 (hereinafter referred to as a foamed PE sheet 24), and a bonding surface 24A to the leather 21 is subjected to corona treatment. The foamed PE sheet 24 is bonded to the genuine leather 21 with an adhesive 23.

  Here, in this embodiment, the corona treatment is not performed on the opposite side of the foamed PE sheet 24 from the genuine leather 21, that is, the surface facing the core portion 15 side, and the foamed PE sheet 24 is not fixed to the core portion 15. As a result, the backing material 22 can slide on the core portion 15.

  Specifically, as shown in the change from FIG. 4 (A) to FIG. 4 (B), the backing material 22 is subjected to a load F in a direction deviating from the backing material 22 on the genuine leather 21. The load F is slidably contacted with the core portion 15 so as to release the load F from the genuine leather 21. Thereby, in the headrest 10 of this embodiment, it can suppress that the load F concentrates on the genuine leather 21, and can suppress a silver surface floating. In detail, the lining material 22 comes into sliding contact before the recesses or wrinkles are generated in the genuine leather 21 subjected to the load F.

  The description regarding the configuration of the headrest 10 has been described above. Next, a method for manufacturing the headrest 10 will be described.

  In order to manufacture the headrest 10, first, the skin material 20 is sewed into a bag shape, and the top material of the stay 12 is inserted into the bag-shaped skin material 20 so that the skin material 20 and the stay 12 are formed by foam molding. Set in mold 30. The skin material 20 is disposed such that the bottom is on the upper side, and a raw material inlet 20A is formed at the bottom. Further, the leg 12 </ b> A of the stay 12 penetrates the bottom of the skin material 20 and protrudes upward from the foaming mold 30. The foam mold 30 is a known mold used for skin integral foam molding, and has, for example, a movable mold 32 that can be rotated with respect to a fixed mold 31, and the fixed mold 31 and the movable mold. In the upper part of 32, a lid mold 33, 34 is provided.

  Next, the raw material injection nozzle 36 is inserted into the raw material injection port 20A, the foamed urethane raw material 35 is injected into the inside of the skin material 20 (see FIG. 5), and the foamed urethane raw material 35 is foamed by heating the foam molding die 30. Let Then, the core part 15 is foam-molded inside the skin material 20, and the headrest 10 is obtained (refer FIG. 6).

  Here, as described above, the backing material 22 is composed of a closed-cell foamed PE sheet 24, and the surface of the foamed PE sheet 24 on the core portion 15 side is not subjected to corona treatment. Therefore, the foamed urethane raw material 35 (core portion 15) does not adhere to the backing material 22 during the foaming process.

  By the way, in the headrest 10 removed from the foaming mold 30, the backing material 22 and the core portion 15 are in close contact with each other by foam expansion, although they are not fixed. Therefore, in the present embodiment, the following processing is performed in order to separate the backing material 22 that is in close contact with the core portion 15 from the core portion 15. That is, as shown in FIG. 7, the air blowing nozzle 40 is inserted through the nozzle insertion hole 40 </ b> A provided in the skin material 20, and the tip of the air blowing nozzle 40 is arranged at the boundary portion between the backing material 22 and the core portion 15. To do. Then, air is blown from the tip of the air blowing nozzle 40 to form a gap 41 between the backing material 22 and the core portion 15.

  Here, the gap 41 may partially remain between the backing material 22 and the core portion 15 even after the air blowing is finished, or disappears when the backing material 22 and the core portion 15 come into contact again. May be. In any case, the backing material 22 can be easily slid in contact with the state before air is blown. 3 and 4, a portion of the skin material 20 that does not have the gap 41 between the core portion 15 is shown.

  The nozzle insertion hole 40A for inserting the air blowing nozzle 40 into the skin material 20 may use a stay hole (not shown) for inserting the leg portion 12A of the stay 12 into the skin material 20. Alternatively, a raw material inlet 20A (see FIG. 6) for injecting the urethane foam raw material 35 into the skin material 20 may be used. The nozzle insertion hole 40A may be provided separately from the raw material injection port 20A and the stay hole.

  This completes the description of the method for manufacturing the headrest 10. Next, the effect of the headrest 10 and the method for manufacturing the headrest 10 will be described.

  In the headrest 10 of the present embodiment, when a load F in a direction deviating from the backing material 22 is applied to the leather 21, the backing material 22 is in sliding contact with the core portion 15 so as to release the load F. The load F no longer concentrates on the surface 21, and the silver surface floating can be suppressed.

  Moreover, in the method of manufacturing the headrest 10 of the present embodiment, after the core portion 15 is foam-molded, air is blown between the backing material 22 and the core portion 15, so that the space between the backing material 22 and the core portion 15 is obtained. Since the gap 41 is once formed, the backing material 22 can be easily slidably contacted with the core portion 15.

[Second Embodiment]
Hereinafter, a second embodiment of the present invention will be described with reference to FIG. The present embodiment is a modification of the first embodiment, and the configuration of the backing material is mainly different. Specifically, as shown in FIG. 8, in the headrest 10V of the present embodiment, the backing material 22V has a polyurethane film 27 (this book) on both sides of the foamed polyurethane slab 26 (corresponding to the “foamed resin sheet” of the present invention). It corresponds to the “resin film” of the invention.).

  Of the backing material 22 </ b> V, the polyurethane film 27 disposed on the genuine leather 21 side is bonded to the back surface of the genuine leather 21 with an adhesive 23. On the other hand, a release agent 28 for polyurethane foam is applied to the surface of the polyurethane film 27 disposed on the side opposite to the genuine leather 21 in the backing material 22V, that is, on the core portion 15 side, on the core portion 15 side. Yes. As a result, the backing material 22V and the core portion 15 do not adhere to each other, and the load F deviated from the backing material 22 to the leather 21 as in the first embodiment (see FIGS. 4A and 4 of the first embodiment). (See (B)), it is possible to make sliding contact with the core portion 15 so that the load F is released. In addition, the polyurethane film 27 arrange | positioned at the genuine leather 21 side does not need to be provided.

  Since the other structure of the headrest 10V is the same as that of the headrest 10 of the first embodiment, description thereof is omitted by attaching the same reference numerals.

  Next, a method for manufacturing the headrest 10V will be described. In order to manufacture the headrest 10V, first, the skin material 20V is formed by bonding the backing material 22V to the genuine leather 21 with the adhesive 23 as in the first embodiment. And after apply | coating the mold release agent 28 to the surface on the opposite side to the genuine leather 21 of the lining material 22V, the skin material 20V is sewn in a bag shape. And it sets to the foaming metal mold | die 30 in the state which inserted the stay 12 in the bag-shaped skin material 20V.

  Next, the urethane raw material 35 is injected from the raw material inlet 20A of the skin material 20V, and the core portion 15 is foam-molded. At this time, since the release agent 28 is applied to the surface of the polyurethane film 27 disposed on the core portion 15 side of the backing material 22V, the foamed urethane raw material 35 (core The portion 15) does not adhere to the backing material 22, and the backing material 22 can come into sliding contact with the core portion 15. Thereby, the headrest 10V is obtained.

  The description regarding the headrest 10V of this embodiment and the manufacturing method of the headrest 10V has been described above. According to the headrest 10V of the present embodiment, the same effects as those of the first embodiment can be obtained.

[Other Embodiments]
The present invention is not limited to the above-described embodiment. For example, the embodiments described below are also included in the technical scope of the present invention, and various modifications are possible within the scope of the invention other than the following. It can be changed and implemented.

  (1) In the said embodiment, although the example which applied this invention to the headrest was shown, you may apply this invention to an armrest, a seat cushion, a seat back etc., for example.

  (2) In the above-described embodiment, an example in which the genuine leather 21 is used as the “leather” of the present invention has been described. However, artificial leather made to resemble genuine leather may be used.

  (3) In the above embodiment, the lining materials 22 and 22V are in sliding contact with the core portion 15 before the recesses and wrinkles are generated in the leather 21 that has received the load F. After the recesses and wrinkles are once generated, they may be brought into sliding contact. Even in such a configuration, the concave portions and wrinkles once generated in the genuine leather 21 due to the sliding contact of the backing material 22 can be eliminated, so that the floating of the silver surface can be suppressed.

  (4) In the first embodiment, air is blown into the boundary portion between the backing material 22 and the core portion 15 into the headrest 10 after being removed from the foaming mold 30, but the headrest body 10 </ b> H is massaged. So-called crushing may be performed.

10,10V Headrest 15 Core 20,20V Skin material 21 Genuine leather (leather)
22,22V Lining material 24 Foamed polyethylene resin sheet 26 Foamed polyurethane slab (foamed resin sheet)
27 Polyurethane film (resin film)
28 Release agent

Claims (5)

In the skin-integrated foam-molded product formed by sewing the skin material with the backing material bonded to the leather into a bag shape, and foam-molding the core inside the bag-shaped skin material,
A skin-integrated foam-molded article, wherein the backing material is slidable against the core portion.   The skin-integrated foam-molded article according to claim 1, wherein the backing material is made of a foamed polyolefin resin, and a corona treatment is applied only to a surface to be bonded to the leather.   The skin-integrated foam-molded article according to claim 2, wherein the foamed polyolefin resin is a foamed polyethylene resin.   The backing material has a structure in which a resin film is bonded to a surface of the foamed resin sheet on the core portion side, and a release agent is applied to the surface of the resin film on the core portion side. Item 1. The skin-integrated foam-molded article according to Item 1. In the manufacturing method of the skin-integrated foam-molded product in which the skin material with the backing material bonded to the leather is sewn into a bag shape, and the core portion is foam-molded inside the bag-shaped skin material,
The lining material is made of a foamed polyolefin resin, and the corona treatment is performed only on the bonding surface with the leather,
Crushing is performed after foam-molding the core part, or air is blown between the backing material and the core part.

Images