JP2016182769A - Method and apparatus for manufacturing foam molded body for vehicle seat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide, in a method for manufacturing a foam molded body by injecting a foam resin raw-material into the inside of a skin, and foaming and curing thereof, a method for manufacturing a foam molded body for a vehicle seat, in which the appearance of the finished foam molded body is not impaired even when a skin of one layer structure is applied.SOLUTION: Provided is a method for manufacturing a foam molded body for a vehicle seat, including: a resin injection step for injecting a foamable resin into the inside of a skin 4 that is formed into a bag-shape from a flexible one layer structure skin material; a resin foaming step for foaming the foamable resin into a predetermined shape; and a resin curing step for curing the foamable resin foamed into a predetermined shape. The skin 4 formed into a bag shape has a long opening K, and the opening K is pulled from the inside to the outside at both ends in the longitudinal direction of the opening K during at least one of resin injection step, resin foaming step or resin curing step. Thereby, the leakage of the resin through the opening during resin injection step, etc., is prevented.SELECTED DRAWING: Figure 11

Description

  The present invention relates to a manufacturing method and a manufacturing apparatus for manufacturing a foamed molded body for a vehicle seat such as a headrest or an armrest.

  The above-mentioned foamed molded article for a vehicle seat is an apparatus for a vehicle seat in which a foamed resin that has been foamed into a predetermined shape is covered with a skin. This foaming molding is a headrest, an armrest, etc., for example. The headrest is a vehicle device that receives the head of a seated person seated on the vehicle seat. The armrest is a vehicle device that receives the arm of a seated person seated on the vehicle seat.

(Patent Document 1)
Conventionally, according to Patent Document 1, a foam molded body such as a headrest is known. In this foamed molded product, a skin containing a stay (ie, a support) is placed in a mold, and a foamed resin raw material is injected into this skin, and the foamed resin raw material is contained in a state where the stay is built (ie, inserted). The foamed molded body is formed by foaming and curing.

  In this conventional foamed molded article, an opening for injecting the foamed resin material is formed by a pair of tongue pieces (that is, an overhanging portion), and the foamed resin material is injected into the skin through the opening. When manufacturing this conventional foamed molded article, in order to prevent the foamed resin material from leaking out from the opening when the foamed resin material is injected, foamed and cured, the plate-shaped jig is opened. The foamed resin raw material is injected, foamed, and cured in the state of being inserted into.

(Patent Document 2)
Conventionally, Patent Reference 2 discloses a headrest using a foamable resin. In this headrest, an annular band having an opening projects from the main body of the skin. A foamed resin material is injected into the skin through the opening of the annular band.

  When manufacturing this conventional headrest, in order to prevent the foamed resin raw material from leaking out from the opening when the foamed resin raw material is injected, foamed and cured, the pulling resin is used in the longitudinal direction of the opening. The foamed resin material is injected, foamed, and cured with the opening closed by pulling both ends.

Japanese Patent Laid-Open No. 7-031759 JP 2007-050621 A

  In the headrest disclosed in Patent Document 1 and Patent Document 2, that is, the foamed molded body, the skin covering the resin after foaming has a multilayer structure. For example, a two-layer structure in which a padding (that is, a pad) is laminated on a skin material such as fabric or leather, or a three-layer structure in which a film such as polyurethane or polyethylene is laminated on a skin material. Was used.

  By the way, although it is not common at present, the use of a skin made of a single-layer skin material in a foamed molded product for vehicle seats has been studied. A single layer structure of the skin leads to lower component costs, lower manufacturing costs, and lower management costs, and is highly expected.

  However, when a single-layer skin is applied in the conventional manufacturing method in which the foamed resin raw material is injected while the opening is supported by the plate-like jig as in Patent Document 1, the single-layer skin is applied. However, there is a problem that the quality of the finished foamed molded product, for example, the headrest is pushed in the vicinity of the opening of the headrest, and the quality of the product is deteriorated.

  On the other hand, Patent Document 2 discloses a conventional manufacturing method in which a foamed resin raw material is injected, foamed, and cured in a state where the opening is closed by pulling both ends in the longitudinal direction of the opening with a pulling member. However, the technique of applying this method to the skin having a single layer structure is not mentioned.

  The present invention has been made in view of the above-mentioned problems in the conventional apparatus, and is a manufacturing method in which a foamed molded article is manufactured by injecting a foamed resin raw material into the inside of the skin and foaming and curing the raw material. An object of the present invention is to provide a method and an apparatus for producing a foamed molded product for vehicle seats in which the appearance of the finished foamed molded product is not impaired even when a skin having a single layer structure is applied.

  According to the present invention, there is provided a method for manufacturing a foamed molded article for a vehicle seat, a resin injecting step of injecting a foamable resin into a bag formed of a flexible single-layer skin material, and a bag A vehicle having a resin injecting step of injecting a foamable resin into the inner skin, a resin foaming step of foaming the foamable resin into a predetermined shape, and a resin curing step of curing the foamable resin foamed into the predetermined shape In the method for producing a foamed molded product for a sheet, the skin is formed of a flexible single-layer skin material, the skin formed in a bag shape has a long opening, and the resin injecting step, In at least one of the resin foaming step and the resin curing step, the opening can be prevented from opening from the inside to the outside at both ends in the longitudinal direction of the opening and in a direction intersecting the longitudinal direction. And wherein the pull it in.

  The manufacturing method of the foaming molding of the present invention is a manufacturing method suitable for manufacturing a foaming molding using the skin of 1 layer structure. The skin with a single-layer structure has a low material cost, a low manufacturing cost, a low management cost, and is very advantageous as a skin for a foam molded article. However, since the skin having a single layer structure has low rigidity, there is a problem that the opening provided in the skin is easily deformed when a foamed resin material is injected into the skin, foamed, and further cured. When the opening is deformed, the foamed resin material may leak out through the opening.

  In the conventional manufacturing method, there is a method of preventing deformation of the opening by inserting a plate-like jig into the opening. However, there is a problem in that the imprint of the plate-shaped jig remains in the single-layer structure skin. On the other hand, according to the present invention, when both ends of the opening are pulled to the outside and an object such as a plate-shaped jig does not exist in the opening, a skin with a single-layer structure that easily has a mark is used. However, it can prevent imprints on the epidermis. Thereby, it can prevent that the external appearance of a foaming molding is impaired.

  In one invention aspect of the method for manufacturing a foam molded body for a vehicle seat according to the present invention, in the resin foaming step, the foamable resin is foamed into a predetermined shape inside the foam mold, and the foam mold includes An opening tension means is provided, and the opening tension means can prevent the opening from opening in a direction perpendicular to the longitudinal direction in at least one of the resin injection process, the resin foaming process, and the resin curing process. With this force, the opening is pulled from the inside to the outside at both ends in the longitudinal direction of the opening.

  According to this aspect of the invention, since the foaming mold provided with the opening tension means is used, the operation of pulling both ends of the opening can be stably performed under certain conditions.

  In another invention aspect of the method for manufacturing a foam molded article for a vehicle seat according to the present invention, the opening tension means is provided on a movable member provided inside and outside the foam molding die, and provided on the movable member. A protruding piece and an elastic member that urges the movable member, and the protruding piece is provided at a position where it can enter the opening of the skin placed in the foaming mold, The elastic member elastically biases the movable member so that the protruding piece pulls the opening of the skin outward.

  According to this aspect of the invention, since the opening is pulled by the projecting piece under the elastic force of the elastic member, the operation of pulling both ends of the opening can be stably performed under certain conditions.

  In still another aspect of the method for manufacturing a vehicle seat foam molded body according to the present invention, the movable member may extend in the direction in which the skin opening placed in the foam mold (for example, left and right in FIG. 11). Direction) and extends outward from the side surface of the foam mold (for example, the left and right side surfaces in FIG. 11), and the movable member rotates about a center line intersecting the surface of the foam mold By doing so, the protruding piece rotates between a position where the protruding piece enters the opening of the epidermis and a position where the protruding piece exits from the opening of the epidermis.

  According to this aspect of the invention, the movable member extends outward from the side surface of the foam mold, and the movable member is configured to rotate parallel to the surface of the foam mold. The operation of putting the projecting piece into and out of the skin opening becomes very easy.

  In still another invention aspect of the method for manufacturing a foam molded article for a vehicle seat according to the present invention, the movable member is an elongated rod-like member, and the protruding piece is provided at the tip of the rod-like member. According to this aspect of the present invention, it becomes easier to perform the operation of putting the protruding piece of the movable member into and out of the opening of the skin.

  Next, an apparatus for manufacturing a foam molded body for a vehicle seat according to the present invention includes a foam molding die having a cavity that is formed in a bag shape and into which a skin having a long opening is mounted, and the opening of the skin. An opening tension means for pulling the opening from the inside to the outside at both ends in the longitudinal direction of the opening with a force capable of preventing the opening of the opening in a direction perpendicular to the longitudinal direction. In the manufacturing apparatus, the opening pulling means includes a movable member provided between the inside and the outside of the foaming mold, a projecting piece provided on the movable member, and an elastic member that biases the movable member. The movable member has a side surface (for example, left and right in FIG. 11) that intersects the extending direction (for example, the horizontal direction in FIG. 11) of the opening of the skin placed in the foam mold. Side of And the movable member is rotated around a center line intersecting the surface of the foaming mold so that the protruding piece enters the opening of the skin and the protruding piece. Rotates between the position where it comes out of the opening of the epidermis.

  According to the production apparatus of the present invention, the foamed resin material is injected, foamed and cured while pulling the skin opening from both sides by the opening pulling means. It is possible to prevent the foamed resin material from leaking out.

  Further, according to the manufacturing apparatus of the present invention, the movable member extends outward from the side surface of the foam mold, and the movable member is configured to rotate in parallel with the surface of the foam mold. It becomes very easy to perform the operation of putting the protruding piece of the movable member into and out of the opening of the skin.

  In one aspect of the manufacturing apparatus of a foam molded body for a vehicle seat according to the present invention, the movable member is an elongated rod-shaped member, and the protruding piece is provided at the tip of the rod-shaped member. According to this aspect of the present invention, it becomes easier to perform the operation of putting the protruding piece of the movable member into and out of the opening of the skin.

  The manufacturing method of the foaming molding of the present invention is a manufacturing method suitable for manufacturing a foaming molding using the skin of 1 layer structure. The skin with a single-layer structure has a low material cost, a low manufacturing cost, a low management cost, and is very advantageous as a skin for a foam molded article. However, since the skin having a single layer structure has low rigidity, there is a problem that the opening provided in the skin is easily deformed when a foamed resin material is injected into the skin, foamed, and further cured. When the opening is deformed, the foamed resin material may leak out through the opening.

  In a conventional method for manufacturing a foamed molded article for a vehicle seat, there is a method of preventing deformation of the opening by inserting a plate-like jig into the opening. However, there is a problem in that the imprint of the plate-shaped jig remains in the single-layer structure skin. On the other hand, according to the method for manufacturing a foamed molded product for a vehicle seat according to the present invention, both ends of the opening are pulled outward, and an object such as a plate-shaped jig does not exist in the opening. Even when a skin having a single-layer structure that is easy to stick is used, it is possible to prevent a mark from being left on the skin. Thereby, it can prevent that the external appearance of a foaming molding is impaired.

  According to the foamed molded product manufacturing apparatus of the present invention, the foamed resin material is injected, foamed and cured while pulling the opening of the skin from both sides by the opening pulling means. In addition, it is possible to prevent the foamed resin material from leaking from the opening of the skin.

  Further, according to the manufacturing apparatus of the present invention, the movable member extends outward from the side surface of the foam mold, and the movable member is configured to rotate in parallel with the surface of the foam mold. It becomes very easy to perform the operation of putting the protruding piece of the movable member into and out of the opening of the skin.

It is a perspective view which shows an example of the headrest which is an example of the foaming molding manufactured by the manufacturing method of the foaming molding for vehicle seats which concerns on this invention. It is process drawing which shows one Embodiment of the manufacturing method of the foaming molding for vehicle seats which concerns on this invention. It is a top view which shows the state before sewing of the skin used with the headrest of FIG. It is a perspective view which shows the state in which the skin for the headrest of FIG. 1 formed by stitching together the skin material shown in FIG. 3 was turned over. It is a perspective view which shows the state which turned over the skin of FIG. (A) schematically shows a curve-shaped sewing process used in the present invention, and (b) schematically shows a comparative example of the sewing process. It is a perspective view which shows the skin assembly set to the state with which it mounts | wears with the cavity of a foaming mold. It is a perspective view which shows the main processes in the manufacturing method of the foaming molding for vehicle seats which concerns on this invention. It is a perspective view which shows one process in the manufacturing method of the foaming molding for vehicle seats which concerns on this invention. FIG. 10 is a perspective view illustrating a process subsequent to FIG. 9. FIG. 11 is a perspective view illustrating a process subsequent to FIG. 10.

  Hereinafter, the manufacturing method and manufacturing apparatus of a foamed molded product for a vehicle seat according to the present invention will be described based on embodiments. Of course, the present invention is not limited to this embodiment. In addition, in the drawings attached to the present specification, components may be shown in different ratios from actual ones in order to show characteristic parts in an easy-to-understand manner.

(Headrest configuration)
First, the structure of the headrest which is an example of the foaming molding for vehicle seats is demonstrated. FIG. 1 shows an example of a headrest. The headrest 1 includes a U-shaped or U-shaped metal frame 2, a pad 3 as a resin after foaming provided around the frame 2, and a skin 4 covering the entire pad 3. Have.

  The frame 2 has column parts 2a and 2b that are exposed to the outside of the skin 4, and a connecting part 2c that connects the column part 2a and the column part 2b. The pad 3 is a resin in which urethane, which is a foamable resin, is foamed and cured to have a predetermined shape. The skin 4 has a front skin material 4a, a right side skin material 4b on the right side for the seated person, and a left side skin material 4c on the left side for the seated person.

(Headrest manufacturing process)
The headrest 1 in FIG. 1 is manufactured, for example, by a manufacturing method shown as a process chart in FIG. This manufacturing method includes a skin creation step P1, a pretreatment step (ie, a skin assembly creation step) P2, a skin assembly setting step P3, a urethane treatment step P4, and a product removal step P5. And have.

(Skin making process)
The skin creation step P1 is a step of creating the skin 4 of FIG. Specifically, as shown in FIG. 3, first, a front skin material 4a, a right side skin material 4b, and a left side skin material 4c having a predetermined shape are cut out from one skin material. The frame insertion hole 7 and the injection nozzle insertion hole 14 which are holes for inserting the frame 2 in FIG. 1 are also cut out.

  The skin material generally has a case of one layer and a case of multilayer. The one-layer skin material is formed of, for example, a fabric such as a woven fabric or a knitted fabric, leather, synthetic leather, or the like (hereinafter referred to as “one-layer material”). The two-layer material is, for example, a material obtained by stacking wadding (that is, padding, padding, etc.) on the one-layer material. When covering the pad 3, the padding contacts the pad 3. The wadding is, for example, a urethane foam material having a thickness of 3 to 5 mm. The three-layer material is, for example, a material obtained by laminating a wadding on the one-layer material described above and further laminating a film thereon. When covering the pad 3, the film contacts the pad 3. The film is, for example, a polyurethane film or a polyethylene film. The thickness of the film is, for example, 30 to 50 μm. In this embodiment, a single-layer skin material is used.

  In FIG. 3, after the front skin material 4a is bent around the line X0, the front skin material 4a, the right side skin material 4b, and the left side skin material 4c are sewn along the alternate long and short dash line G1, and further the front skin material 4a. By stitching the protruding pieces 4d1 and the protruding pieces 4d2 along the alternate long and short dash line G2, a skin 4 (inverted state) as shown in FIG. 4 is formed. The state shown in FIG. 4 is a state in which the back surface of the skin 4 appears on the front side, and the sewing line G1 and the sewing line G2 appear on the front side.

  A portion where the projecting piece 4d1 and the projecting piece 4d2 are sewn together by a sewing line G2 forms an overhanging portion 9 projecting from the main body portion 8 of the skin 4. The main body 8 is a portion that covers the pad 3 that is a resin after foaming. In the overhang portion 9, the tip side L between one sewing line G2 and the other sewing line G2 is not stitched, and is a tip opening. Further, the root side K between one sewing line G2 and the other sewing line G2 is not sewn, and is a root opening.

  FIG. 5 shows a state in which the skin 4 is turned upside down through the root opening K and the tip opening L in FIG. That is, the state shown in FIG. 5 is a state in which the surface of the skin 4 appears on the front side, and the sewing line G1 and the sewing line G2 are hidden on the back side. In FIG. 4, the overhang portion 9 formed by the projecting pieces 4 d 1 and 4 d 2 projects outside the main body portion 8 of the skin 4, but the overhang portion 9 projects over the inside of the main body portion 8 of the skin 4 in FIG. 5. .

  In FIG. 4, the boundary portion A between the body portion 8 of the skin 4 and the overhang portion 9 of the skin 4 is stitched together by a curved sewing line G3. Specifically, as shown in FIG. 3, the boundary portion A is sewn into a partial shape of a circle. More specifically, the boundary portion A is sewn into a shape of approximately ¼ of a circle (a circle corresponding to an angle of 90 °). The radius of this circle is set to 10 mm or more. The curved sewing line G3 to the edge of the front skin material 4a are stitched together by a linear sewing line.

  In the current sewing machine, when the seam has a circular shape with a radius of 10 mm or more, as shown in FIG. 6 (a), the sewing needle 5 is sewn while moving smoothly along the circular shape. Work can be done. On the other hand, when the radius of the seam is less than 10 mm, it is difficult to perform the sewing operation while continuously moving the sewing needle as shown in FIG. It is necessary to change the sewing direction N of the needle by rotating the sewing product while dropping the needle 5 each time the needle 5 is moved. In this case, the needle hole was inevitably enlarged when the sewing product was rotated. However, in this embodiment, since the radius of the curved shape of the seam of the boundary portion A in FIGS. 3 and 4 is set to 10 mm or more, a large needle hole is not formed in the boundary portion A.

  In a general sewing operation, the sewing process is performed by moving the needle along the outer edge line using the outer edge line of the sewing as a mark. Therefore, when the seam of the boundary portion A is circular as described above, it is desirable to cut the outer edge line of the skin 4 corresponding to the boundary portion A into a circular shape having a radius of 10 mm or more in advance. For this reason, in this embodiment, a circular shape having a radius of 10 mm or more is formed in a corresponding portion of a pattern used when cutting out the front skin material 4a of FIG. 3 from one material, and the front skin material is based on this pattern. The boundary part A of 4a is cut out.

(Preprocessing)
In the pretreatment step P2 of FIG. 2, the support 2a or the support 2b of the frame 2 of FIG. 1 is inserted into one of the frame insertion holes 7 of the skin 4 of FIG. 5, and further, as shown in FIG. Is inserted into the inside of the skin 4, and then the column part 2 a or 2 b is extracted from the other side of the frame insertion hole 7, the two column parts 2 a and 2 b are outside the skin 4, and the connecting part 2 c is Keep it inside. Next, the tip of the injection nozzle 12 is inserted into the skin 4. Thereby, the skin assembly 13 is created.

(Set process to mold)
Next, in the setting process P3 to the mold shown in FIG. 2, the skin assembly 13 is set in the cavity of the foaming mold 16 as shown in FIG. Next, as shown in FIG. 8B, the foaming mold 16 is closed. The cavity has a concave shape that matches the shape of the desired headrest.

  The foam molding die 16 has a lower die 16a and an upper die 16b. Opening tensioners 18a and 18b as opening tension means are provided at the open / close end of the lower mold 16a. These opening tensioners 18a and 18b have a rod-shaped member 19 as a movable member, as shown in FIG. The rod-shaped member 19 passes through the rectangular frame member 20. The frame member 20 is provided so as to be rotatable about a line X1 that intersects the surface of the lower mold 16a of the foaming mold 16 (orthogonal in the present embodiment). As a result, the rod-shaped member 19 is provided on the lower mold 16a so as to be rotatable about the line X1, as indicated by an arrow J-J '. At the tip of the rod-shaped member 19, a protruding piece 22 is provided that protrudes toward the inner side of the lower mold 16a. Inside the frame member 20, a compression spring 21 as an elastic member is provided around the rod-shaped member 19. The compression spring 21 urges the rod-shaped member 19 backward with a predetermined spring force as indicated by an arrow H.

  When the skin assembly 13 of FIG. 7 is mounted in the cavity 23 of the lower mold 16a of the foaming mold 16 of FIG. 9, the rod-shaped members 19 of the left and right opening tensioners 18a and 18b are moved outward as shown in FIG. The skin assembly 13 is placed in the cavity 23 after being rotated (in the direction of arrow J) (that is, in a state where the opening tensioners 18 a and 18 b are opened). The rod-shaped member 19 extends to the outside from the left and right side surfaces 16c and 16d of the foam mold that intersects the extending direction of the opening K of the skin 4 placed in the foam mold 16 (left and right direction in FIG. 10). .

  After placing the skin 4 in the cavity 23, the operator pushes the rod-shaped member 19 forward against the spring force of the compression spring 21 as indicated by an arrow M, and moves the projecting piece 22 forward. Next, the operator rotates the rod-shaped member 19 toward the inner side (arrow J ′ side) of the lower mold 16 a to insert the protruding piece 22 into the root opening K of the skin 4. After the insertion, when the operator removes his / her hand from the bar-shaped member 19, the bar-shaped member 19 is linearly moved back and forth in the outer direction of the lower mold 16a as shown by an arrow H by the spring force of the compression spring 21 as shown in FIG. .

  Thus, when the rod-shaped members 19 of the opening pullers 18a, 18b on the left and right sides move outward, the projecting pieces 22 provided at the tips of the rod-shaped members 19 pull the root opening K of the skin 4 to the left and right sides. The opening K is closed by this pulling. After the above processing is completed, the upper mold 16b of the foam mold 16 is closed to the lower mold 16a in FIG. 8A, and the foam mold 16 is closed as shown in FIG. 8B.

(Urethane treatment process)
Next, in the urethane treatment step P4 of FIG. 2, as shown in FIG. 8B, the head portion 17 of the urethane injector is pressed against the mold, and urethane is injected into the mold. Furthermore, after the urethane injection is completed, the mixture is held at room temperature for a certain period of time. Thereby, urethane foams and hardens within the outer skin 4, and a urethane foam conforming to the shape of the cavity of the mold is formed. The shape of this urethane foam is the desired headrest shape.

(Product removal process)
Next, in the product removal step P5 in FIG. 2, the mold 16 in FIG. 8B is opened, and in FIG. 11, the rod-shaped member 19 is rotated outward (arrow J side) and extracted from the skin 4, and after foaming By taking out the skin assembly 13 containing the urethane resin and further removing the injection nozzle 12, a finished product of the headrest 1 as shown in FIG. 1 is obtained as a foam molded body. In the headrest 1, the main body 8 of the skin 4 covers the urethane foam pad 3 that is a resin after foaming. The overhanging portion 9 of the epidermis 4 protrudes toward the inside of the main body portion 8. The overhanging portion 9 is formed by stitching together the two projecting pieces 4d1 and 4d2 of the front skin material 4a shown in FIG. 3 along a sewing line G2. The overhanging portion 9 has a root opening K and a tip opening L. In the process in which the pad 3 is foamed, the overhanging portion 9 in the main body portion 8 is pressed from above and below by the foaming pad 3 to open the opening. K and the opening L are automatically closed. For this reason, the urethane resin does not leak from the root opening K and the tip opening L.

  In the headrest of the present embodiment described above, as shown in FIG. 4, the boundary portion A between the main body portion 8 of the skin 4 and the overhanging portion 9 of the skin 4 is formed with a circular sewing line G3, that is, a curved shape. Sewing is performed at the sewing line G3. More specifically, the boundary portion A is sewn into a circular shape having a radius of 10 mm or more. If the radius of the seam is set to less than 10 mm, the stitching process changes the direction of travel by rotating the sewing item with the needle dropped every short interval d, as shown in FIG. 6 (b). Had to do while. If it carries out like this, when rotating a sewing thing centering on a needle | hook, there exists a possibility that a large needle hole may be formed in a sewing thing.

  In this way, the skin assembly 13 is formed as shown in FIG. 7 on the basis of the skin 4 having a large needle hole at the boundary portion A between the main body portion 8 and the overhanging portion 9 of the skin 4, and based on this skin assembly 13. When the headrest 1 shown in FIG. 1 is created, urethane oozes out from a large needle hole during the urethane treatment step shown in FIG. 8B, and as a result, the appearance of the headrest 1 may be impaired.

  On the other hand, if the boundary portion A is sewn with a continuous circular sewing line G3, that is, a curved sewing line G3 as in the present embodiment shown in FIGS. A large needle hole can be prevented from occurring in A, and as a result, no seepage of urethane resin occurs at the boundary portion A between the overhang portion 9 and the main body portion 8, and the appearance of the headrest can be maintained clean. In particular, the skin 4 of this embodiment is formed of a single-layer skin material, and the needle hole tends to be large. However, according to this embodiment in which the boundary portion A is sewn with a curved sewing line G3, one layer is formed. Generation of a large needle hole can be prevented even in the structure skin 4.

  Further, in the present embodiment, as shown in FIG. 11, the opening stretcher 18a, 18b pulls the opening K of the epidermis 4 to the left and right sides, and closes the opening K to perform injection, foaming and curing of the foamed resin material. Decided to do. As a result, it is possible to reliably prevent the resin from leaking from the opening K, and as a result, the appearance of the headrest 1 as a finished product can be maintained clean.

  Since the skin 4 of the present embodiment is formed of a single-layer skin material, when the opening is supported by a plate-like jig as in Patent Document 2 (Japanese Patent Laid-Open No. 7-031759), The headrest as a finished product has a mark pushed by a plate-shaped jig, which may impair the appearance. On the other hand, in this embodiment, without using a plate-shaped jig, as shown in FIG. 11, injection, foaming and curing of the foamed resin raw material are performed while pulling the opening K from both the left and right sides by the opening tensioners 18 a and 18 b. As a result, it was no longer left behind on the headrest as a finished product.

  Furthermore, in this embodiment, as shown in FIGS. 10 and 11, the operator operates the rod-shaped member 19 that protrudes from the side surfaces 16c and 16d instead of the front surface of the foam molding die 16, so that the operation is very easy. It is. Moreover, since the rod-shaped member 19 rotates in parallel with the surface of the lower mold 16a about the rotation center line X1, the operation of putting the protruding piece 22 at the tip of the rod-shaped member 19 into and out of the opening K of the skin 4 is very much. Easy.

(Other embodiments)
The present invention has been described with reference to the preferred embodiments. However, the present invention is not limited to the embodiments, and various modifications can be made within the scope of the invention described in the claims.

  For example, in the above-described embodiment, the boundary portion A between the main body portion 8 of the skin 4 and the overhanging portion 9 of the skin 4 in FIGS. 4 and 5 is sewn with a curved sewing line G3. Alternatively, the boundary portion A may be sewn with a right-angled sewing line.

  In the said embodiment, the headrest was illustrated as a foaming molding for vehicle seats. However, the vehicle seat foam molded body may be anything as long as it is a device in which the foamed resin that has been foamed into a predetermined shape is covered with a skin. An example of such a device is an armrest. The present invention can also be applied to such an armrest.

  In the above embodiment, the compression spring 21 is used as an elastic member in the opening tensioners 18a and 18b in FIG. Instead, a tension spring or an elastic member other than the spring can be used.

  In the above embodiment, as shown in FIG. 9, the two opening tensioners 18 a and 18 b provided with the compression spring 21 that is an elastic member are provided on both the left and right sides of the lower mold 16 a of the foaming mold 16. However, in some cases, the elastic member can be provided only on one of the left and right sides. In short, it is sufficient that an elastic force can be applied to the opening K of the skin 4.

  1. 1. Headrest (foam molded body) Frames, 2a, 2b. Struts, 2c. 2. connecting part; 3. Pad (resin after foaming), Epidermis, 4a. Front skin material, 4b. Right side skin material, 4c. Left side skin material, 4d1, 4d2. 4. Projection piece 6. Sewing needle, 7. Frame insertion hole Body part, 9. 11. overhang, Injection nozzle, 13. Skin assembly, 14. 15. injection nozzle insertion hole; Foam mold 16a. Lower mold, 16b. Upper mold, 16c, 16d. Side, 17. Head portion of urethane injection machine, 18a, 18b. 18. Opening tensioner (opening tension means), 20. Rod-shaped member (movable member) Frame member, 21. Compression spring (elastic member), 22. Protrusions, 23. Cavity, A. A boundary portion, d. A predetermined distance, G1. Main body sewing line, G2. Overhang part sewing line, G3. Curve-shaped sewing line; Root opening, L. Tip opening; Sewing direction, fold line of X0.4a, X1. A line intersecting the lower mold 16a

Claims (7)

A resin injecting step of injecting a foamable resin into the inside of the skin formed of a flexible single-layer skin material;
A resin foaming step of foaming the foamable resin into a predetermined shape;
In a method for producing a foamed molded article for a vehicle seat having a resin curing step of curing a foamable resin foamed into a predetermined shape,
The bag-shaped epidermis has a long opening,
In at least one of the resin injecting step, the resin foaming step, and the resin curing step, opening the opening from the inside to the outside and the direction in which the opening intersects the longitudinal direction at both ends in the longitudinal direction of the opening. A method for producing a foamed molded article for a vehicle seat, characterized by being pulled with a force that can be prevented. In the resin foaming step, the foamable resin is foamed into a predetermined shape inside the foaming mold,
The foam molding die is provided with opening tension means,
The opening pulling means has a force that is large enough to prevent the opening from opening in a direction perpendicular to the longitudinal direction in at least one of the resin injection step, the resin foaming step, and the resin curing step. The method for producing a foamed molded article for a vehicle seat according to claim 1, wherein the opening is pulled from the inside to the outside at both ends in the direction. The opening tension means is
A movable member provided across the interior and exterior of the foam mold;
A projecting piece provided on the movable member;
An elastic member for biasing the movable member,
The protruding piece is provided at a position where it can enter an opening of the skin placed in the foaming mold,
The method of manufacturing a foamed molded article for a vehicle seat according to claim 2, wherein the elastic member elastically biases the movable member so that the protruding piece pulls the opening of the skin outward. The movable member extends to the outside from a side surface of the foam mold that intersects with the extending direction of the opening of the skin placed in the foam mold, and the movable member further includes the foam mold. By rotating about a center line intersecting the surface, the protruding piece rotates between a position where the protruding piece enters the opening of the epidermis and a position where the protruding piece exits the opening of the epidermis. The manufacturing method of the foaming molding for vehicle seats of Claim 3.   5. The method of manufacturing a foam molded body for a vehicle seat according to claim 4, wherein the movable member is an elongated rod-shaped member, and the protruding piece is provided at a tip of the rod-shaped member. A foam molding die having a cavity in which a skin formed with a long opening and having a long opening is mounted;
Opening tension means for pulling the opening from the inside to the outside at both ends in the longitudinal direction of the opening with a force large enough to prevent the opening of the skin from opening in a direction perpendicular to the longitudinal direction. In the production apparatus for foam molded articles,
The opening tension means is
A movable member provided across the interior and exterior of the foam mold;
A projecting piece provided on the movable member;
An elastic member for biasing the movable member,
The movable member extends to the outside from a side surface of the foam mold that intersects with the extending direction of the opening of the skin placed in the foam mold, and the movable member further includes the foam mold. By rotating about a center line intersecting the surface, the protruding piece rotates between a position where the protruding piece enters the opening of the epidermis and a position where the protruding piece exits the opening of the epidermis. An apparatus for producing a foam molded body for a vehicle seat.   The said movable member is an elongate rod-shaped member, The said protrusion is provided in the front-end | tip of the said rod-shaped member, The manufacturing apparatus of the foaming molding for vehicle seats of Claim 6 characterized by the above-mentioned.

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