JP2003251089A - Method for manufacturing cushion material comprising spring structure resin mold - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing, in various thicknesses using a single die, a cushion material comprising a spring structure resin mold, that is recyclable, with a high flexibility of form and size, of low cost, allowing less sinking, causing less fatigue after long-time use, with excellent impact resistance and withstand load performance, and suitable for seats in automobiles, motor-bicycles, bicycles, trains, aircrafts, etc., saddles for horse riding, chairs, sofas, beds, or other things on which humans sit, lie, or ride. <P>SOLUTION: A male die 14 is pushed down by a pantograph jack 15 to tighten the spring structure resin mold 30. A cavity 12 in a female die 11 is set in size to match cases of deep drawing, and the dies are provided with allowance, so that thickness of the cushion material 1 can be varied using the single die by adjusting the stroke of the male die 14. Both deep drawing and shallow drawing can be applied in manufacturing using the single die. Density, spring characteristics, and rigidity can be varied freely. <P>COPYRIGHT: (C)2003,JPO

Description

Description: BACKGROUND OF THE INVENTION [0001] The present invention relates to a spring structure tree.
Regarding the method of manufacturing cushioning material composed of fat molded products,
In addition to being superior in impact resistance and load resistance,
Characteristics and unspecified majority in each field such as shape and size
To meet the detailed needs of automobiles and motorcycles.
Car, bicycle, train or aircraft seats, horse riding
Such as a saddle, chair, sofa or bed for people to sit, sleep or
Is a spring structure that can be applied to anything riding
This is a method of manufacturing cushioning materials made of resin molded products.
In addition, a mold that can be formed into various thicknesses with one type of mold
Manufacturing method of cushioning material composed of resin molded product with spring structure
About the law. 2. Description of the Related Art At present, automobiles, motorcycles, bicycles,
Used for seats and beds in cars and aircraft
Polyurethane foam is the mainstream cushion material.
You. People with or without vibration
Where you sit, sleep or ride
In general, uranium materials are used.
Tanfoam is widely used in all fields,
It is considered that there are few problems in terms of law and cost,
Very high. [0003] As such a cushion material, for example,
In Japanese Patent No. 2995325, the seat portion has a single-layer structure.
The high resilience form
Zirien foam is tolylene diisocyanate (TD
I) in a proportion of 10% by weight or less, with the remainder being diphenyl
Isocyanate consisting of methanediisocyanate
Automotive seat cook made of urethane foam
Cushion pads have been proposed. Patent No. 2548
In No. 477, high melting point polyester fibers are
Cushion structure fused with point thermoplastic elastomer
Structures have been proposed. Also, Japanese Patent Application Laid-Open No. 2000-5101
In No. 1, 1 to 20 denier synthetic fiber or natural fiber
Partially fiber with synthetic rubber adhesive or crosslinkable urethane
Cushions have been proposed. [0004] Generally, urethane foam
In the form, when a person sits, the load concentrates on one place
Therefore, sinking is large, balance is unstable, and long
There are problems such as accumulation of fatigue when sitting for a long period. this
The urethane foam is formed by foaming evenly.
Shape, the density and strength are constant, and
It is difficult to change the strength and density for each part.
And that is the cause. Urethane foam is too flexible
Therefore, the feeling of thrust from the bottom, the feeling of bottoming, and the swinging feeling are large.
Sitting for long periods of time can cause numbness and a feeling of fatigue
Sometimes. For example, in the case of automobiles and motorcycles,
Demands are diversifying from the viewpoint of the production method and structure of polyurethane foam.
However, the density of the material is constant,
When using, the surface pressure distribution changes, so it is not optimal in function.
There is. For urethane foam, foam molding
The spring characteristics are uniform or the type is
And it is difficult to change as necessary. Therefore, ure
Tanform responds to various requirements for spring characteristics
Is difficult. For example, in the case of a motorcycle,
Riding figure for rings, road racing, motocross, etc.
Spring characteristics must be changed according to the force and condition
However, because the seat does not support this,
You need to raise or lower the hips during the line. like this
The center of gravity is increased by increasing the amount of time
There are inconveniences such as an unstable balance. [0005] In addition, depending on the field of use, in particular, automobiles and
When used for motorcycles, etc., the
It is necessary to control the thickness of the cushioning material
You. This means that even if the outer shape is the same,
Thickness differs depending on the model (suspension characteristics)
That's because. Usually, in this case, too, such as shallow drawing, deep drawing, etc.
It is necessary to arrange a large number of dies according to the degree of staking. [0006] Urethane foam is a thermosetting resin.
Is difficult to recycle, and the recycling method
What is made into chips with a crusher by adhesive molding
A material called chip form (ribbon dead form)
To regenerate or burn and recover as thermal energy
Stay. Disposal methods include landfill and incineration.
Soft urethane foam with low bulk density
In landfill disposal, it is difficult to stabilize the ground,
Places are limited. It is also processed into powder and granules and landfilled.
It is possible but costly and time consuming. On the other hand,
During baking, in particular, hydrocyanic acid gas (hydrogen cyanide) is generated.
As a result, the incinerator is greatly damaged and the removal of cyanide gas is
Leaving may also be expensive. Thus, the resai
Due to the relationship with the Kull method, environmental measures are taken for
It will be difficult. [0007] In addition to the above, urethane foam
Also have the following problems. Difficult to wash. During manufacturing
Does the amine catalyst used remain in the foam and give offfensive odor?
It is. In addition, there is no air permeability and heat storage, so
Easy to burn out when focused light is applied continuously for a long time
There is a risk. Low performance for environment. Urethane fo
Of alternative CFCs used as foaming agents during
Expiration date is 2020, but more foamable than alternative CFC
At present, there is no alternative agent with excellent performance. In addition, soft
An isocyanate commonly used in the production of polyurethane foam
One TDI has a concentration of 0.005 in Notification 25 of the Ministry of Labor.
Highly toxic substance determined to be less than ppm
When the control is not thoroughly implemented at the actual manufacturing site.
May harm the health of workers. [0008] Among the above problems, flexible urethane foam
Regarding the characteristics, see the above-mentioned prior art Patent No. 29953.
Although improved in No. 25, it has urethane foam
Other issues remain.
It is also proposed in Japanese Patent No. 2548477.
The cushion structure is made of low melting polyester fiber with high melting point.
Recycled because it is fused with a point thermoplastic elastomer
Is difficult, and the manufacturing method is complicated, and the processing cost is extremely high.
Challenges remain. Also, Japanese Patent Application Laid-Open No. 2000-51011
No. has advantages such as good air permeability and washability,
Poor durability, complicated manufacturing method, extremely high processing cost, etc.
The subject has. In addition, rubber-based adhesives and cross-linkable
Because tongue is a thermosetting resin and not a single composition,
Difficult to recycle. As described above, there are various problems as described above.
While you are a car, motorcycle, bicycle, train
Is a cushion used for seats and beds in aircraft, etc.
It has the same or better performance as urethane foam
And there are no alternative materials that can be manufactured at low cost
Is the current situation. [0010] Therefore, the present invention is difficult to recycle.
In addition, urethane pho
Vehicles, motorcycles, bicycles, trains
Or seats for aircraft, etc., saddles for riding, chairs, sofas
Or used for things such as beds, where people sit, sleep or ride
Spring structure resin molding suitable as a cushion material
To provide a manufacturing method suitable for a cushion material made of a product.
aimed to. In particular, the molding process is easy,
High degree of freedom in size and size, inexpensive, less sinking,
Use it for a long time as it spreads the pressure evenly when sitting down
Responds to various requirements for spring characteristics, such as
Molding with desired physical properties such as load resistance and impact resistance
Products can be easily manufactured and shallow drawn and deep
Manufactures molded products of various thicknesses using one type of die corresponding to drawing
The purpose is to provide a manufacturing method that can
You. [0011] The invention according to claim 1 provides
On the female mold, a solid made of at least thermoplastic resin and
/ Or random loops of hollow continuous and / or short filaments
Contact and entangle the adjacent filaments of the loop or curl
Place a three-dimensional structure with voids of a predetermined bulk density
Under the temperature conditions necessary to soften the three-dimensional structure,
Heating the mold and / or the three-dimensional structure, the female mold and the male mold
The three-dimensional structure is closed with a mold, and the three-dimensional structure is cooled.
Characterized by curing the structure, and wherein the female mold is
Volume corresponding to male stroke in deep drawing
Resin molding with spring structure characterized by being set to
This is a method for manufacturing a cushion material made of a product. "Continuous and / or short filaments" are preferred.
Or general-purpose plastics (polyolefin, polystyrene
Resin, methacrylic resin, polyvinyl chloride, etc.)
Zineering plastics (polyamide, polycarbonate
Sheet, saturated polyester, polyacetal, etc.)
You. For example, polyethylene (hereinafter referred to as PE), polyp
Thermoplastic such as ropylene (hereinafter referred to as PP) or nylon
Preferably, it is made of an elastomer. In particular, polyolefin-based trees such as PE and PP
Fat, vinyl acetate resin (hereinafter referred to as VAC), vinegar
Styrene copolymer (hereinafter referred to as EVA) or styrene pig
A mixture of diene styrene (hereinafter referred to as SBS)
preferable. At this time, the polyolefin resin and VAC or
Is the mixing ratio of the EVA vinegar content of 70 to 97% by weight:
3 to 30% by weight, preferably 80 to 90% by weight: 10 to 10%
20% by weight is preferred. This is because VAC or EVA is 3
If it is less than 30% by weight, the rebound resilience decreases, and more than 30% by weight.
This is because the thermal characteristics deteriorate when the temperature becomes lower. Also polio
The mixing ratio between the refin-based resin and SBS is 50 to 97 weight
%: 3 to 50% by weight, preferably 70 to 90% by weight: 1
0-30% by weight is preferred. In addition, polyolefin-based trees
The fat may be a regenerated resin. The structure of "continuous and / or short filaments" is medium.
It may be real or hollow. Hollow continuous filament and / or
Means that in the case of short filaments, air is trapped in the pipe
The characteristic of the air spring is expressed, and the unique cushioning
It is preferable because it occurs. Buckling can also be prevented. Also, the air
By entering, the rigidity of the three-dimensional structure is maintained. Hollow
May be continuous or discontinuous. One
Having both a hollow portion and a portion in which the hollow portion is closed
For example. Solid streak and medium
The mixture ratio of empty filaments is solid: hollow = 0 to 50:50 to 1
00 is preferred. At this time, a hollow center
Using a wire, cover the outer circumference of the hollow wire with a solid wire
By doing so, the tactile sensation becomes good, which is preferable. [0015] The wire diameter of the "continuous filament and / or short filament" is
For solid filaments, 0.3-3.0 mm, especially 0.
It is preferably from 7 to 1.0 mm. Solid line
Therefore, when the wire diameter is 0.3 mm or less,
As a result, the number of fused portions increases and the porosity decreases. 3.0mm
Above, the filament has too much waist and loops or curls are formed.
It is not formed, the number of fused parts is reduced, and the strength is reduced. Ma
In the case of hollow filaments, 1.0 to 3.0 mm, especially
It is preferably 1.5 to 2.0 mm. Hollow ratio is 1
If it is 0% or less, it does not contribute to weight reduction, and if it is 80% or more,
Performance decreases. [0016] Bulk density of "spring structure resin molded product"
Is 0.005 to 0.08 g / cm ^Three ,Preferably,
0.02-0.06 g / cm ^Three It is preferable that
Bulk density 0.005g / cm ^Three Below, the strength decreases
You. Bulk density 0.08g / cm ^Three With the above, weight reduction was achieved
No elasticity is lost. Also, this spring structure resin
The molded product is not limited to a constant density as a whole,
It may have a dense structure. The bulk density in this case is
In part, 0.005 to 0.03 g / cm ^Three , Preferably
Is 0.008 to 0.03 g / cm ^Three , Especially 0.01 to
0.03g / cm ^Three Is preferred. In the dense part, 0.0
3 to 0.08 g / cm ^Three , Preferably 0.04 to 0.0
7g / cm ^Three , Especially 0.05 to 0.06 g / cm ^Three Is preferred
New Porosity of "spring-structured resin molded product"
Is 96-99%, preferably 97-99%, especially 9
It is preferably from 7 to 98%. As a cushion
High porosity to maintain elasticity and strength and reduce weight
The above range is preferred. [Porosity (%)] = (1- [bulk density] / [density of resin]
Degree]) × 100 [Cushion material] is a multilayer spring structure
It is preferable to be composed of a resin molded product. Also, cook
Applications for automobiles, motorcycles, bicycles, trains
Or aircraft seats, saddles for riding, chairs, soft
Or a bed or the like. Also, the above example
Besides, any place with or without vibration
And cushioning material where people sit, sleep or ride
As a substitute for urethane foam,
Widely available. In particular, vibrations from automobiles and motorcycles
Easy to control thickness even when used where
For each model (suspension characteristics)
It is preferable because it can be suitably handled. The "female type" is preferably made of concrete. Ko
No need for mold release agent by using concrete mold
And the cost of the mold itself is reduced. "Female"
The angle of the taper of the side of
Preferably shallow. In addition, "male type" is cushion material
It is preferable to use the product (base) to which the
New This eliminates the need for a separate male mold
The cost is reduced and the molding accuracy is improved. Said
Cooling includes natural cooling or forced cooling. Forced cooling is water
It is preferable to use Here, the secondary processing of urethane foam will be described.
Is easier and more detailed than urethane foam
Can respond to. Also, because it is compression molded,
Add products, such as forming original ones according to
Value increases. In particular, the thickness of the cushion
Control, so many molds are available
Can meet various product requirements.
Noh. For example, when manufacturing thin cushioning materials
Only need to make the stroke deeper. Conversely, thick cook
When manufacturing cushioning materials, make the strokes shallower.
Good. This allows you to be tailor-made
Etc. can respond to product characteristics and unspecified large number of detailed needs
The cushion material can be easily manufactured. In addition, the spring
Diameter, material, denier, bulk density,
Can freely change the spring characteristics by changing the porosity, etc.
It can also be. In other words, the spring properties of the material
Is constant, but can be squeezed by compression molding.
It can change the cushion function and make the load distribution variable
can do. DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is a perspective view, and FIG.
As shown in the figure and the rear view of FIG.
Is a thermoplastic resin, for example, a polyolefin such as PE or PP.
Mixture of vinyl resin and VAC, EVA or SBS
(For example, thermoplastic elastomer)
Of a spring-structured resin molded product 30 which is a three-dimensional structure
Also manufactured by compression molding as described below
It is. (Description of Resin Molded Product with Spring Structure 30)
First, the spring-structured resin molded product 30 will be described.
You. Spring-structured resin molded product 3 used in this embodiment
0 is a continuous line and / or short line made from the above mixture
Articles (hereinafter simply referred to as “filaments 31”) are randomly entangled.
A three-dimensional structure having a void formed by
Form a plurality of loops or curls (part of FIG. 1)
Minute enlarged view A). In this embodiment, the spring structure
As shown in the cut surface 31a, the resin molded product 30 is a hollow wire.
(See FIG. 1, a partially enlarged view B). Here, the bulk density of this three-dimensional structure is
0.005 to 0.03 g / cm ^Three , Preferably 0.0
08-0.03g / cm ^Three , Especially 0.01 to 0.03 g
/ Cm ^Three It is preferable that In addition, this three-dimensional structure
Has a porosity of 96 to 99%, preferably 97 to 99%.
%, Especially 97 to 98%. (Explanation of the cushion material 1)
The material 1 will be described. The cushion material 1 is
The ring-shaped resin molded product 30 is manufactured by compression molding.
Built. The cushion material 1 in the present embodiment is shown in FIG.
As shown in the side view, mainly motorcycles (for example,
10) cushion material used for the seat
You. The cushion material 1 has the same or different spring characteristics.
2 sheets (upper sheet 2 and lower sheet 3)
It is fixed to the base 4. At this time,
The sheet 2 and the lower sheet 3 are adhered with an adhesive or a double-sided tape.
It is preferred that Spring characteristics, spring structure
Depending on the density, material and / or wire diameter of the resin molded product 30,
It can be variable for each sheet or part. Specifically
Means that the lower layer is hard and the upper layer is soft, etc.
Is preferably changed. For example, in this embodiment, the upper sheet
Reference numeral 2 denotes a flexible structure having lower rigidity than the lower sheet 3. This
The upper sheet is fixed to the lower sheet 3 fixed to the base 4.
Butt 2 touches the buttocks directly when a person gets on it.
is there. At this time, the upper seat 2 is suitable for a posture where a person rides.
Form a swelling part as appropriate to fit
Is preferred. On the other hand, the lower sheet 3 is fixed to the base 4
For this reason, the upper sheet 2 needs to be harder. At this time,
The shape of the cushioning material 1 is maintained by the hardness of the lower sheet 3.
It is also preferable to adopt a structure in which The lower sheet 3 allows the cushioning material 1
Has unique suspension characteristics. For example, Ureta
Conventional seats that used foam
Because the road reaction force (kickback), which is dynamic, is large,
Put the coil spring into the tongue and receive the road surface reaction force
Often. However, in this embodiment, the two layers
With a structure, human load is received by the flexible upper sheet 2.
And the unsprung vibration of the lower sheet 3
I can take it. With this, the contact coil sp
No ring is required. Therefore, it is advantageous in terms of weight and structure
Simple, and also requires special component structures
It becomes. As the bulk is reduced, the center of gravity moment
It also contributes to the stability of the posture. In addition, during compression molding
By adjusting the stroke of the male mold, cushion material
1. Various thicknesses of different shapes or sizes by freely adjusting the thickness
It can also be adapted to suspension. The cushion material 1 is made of a spring structure tree.
Since it is made of the fat molded product 30, the air permeability is excellent. Follow
Needless to say that it doesn't get stuffy,
If air for cooling and heating is ventilated from the cooling and heating duct inside,
The seat of the motorcycle 10 can be equipped with a cooling and heating function.
You. Also, if used as a car seat, special
Compatible with high-end car specifications without using materials. The upper sheet 2 and the lower sheet 3
The cushion material 1 is not limited to the illustrated shape.
Needless to say, it can be formed into an appropriate shape. For example,
The sheet layers may be one layer without overlapping the sheets. C
In the case of overlapping the layers, two or more layers may be used. Also, 2
Of the sheets of layers or more, for example, the sheet of the lower layer is synthesized
It may be made of rubber or the like, but at least one (preferably
Or the upper layer) is preferably made of the above thermoplastic resin.
New In addition, the shape of the raised portion is not limited to this embodiment.
Not. In particular, in each field such as individual shape and size
Product needs, characteristics and unspecified large number of detailed needs.
It is available. Further, a cushion material having a multilayer structure (for example,
On the upper sheet 2) of the cushioning material 1, sewing (hand sewing or
It consists of a resin molded product with a spring structure that has been sewn
Laminate cushioning material and use it as the top sheet
Is also preferable (not shown). In this case, in particular, the traditional mall
Can express complex irregularities and subtle changes that are difficult to mold
Performance in each field, such as individual shapes and sizes.
Stricter to product requirements, characteristics and unspecified large number of detailed needs
It is possible to correspond closely and custom-made depending on the model and body type
You can also do it. For example, motorcycle 10 or car
When using it as a seat, etc.
A driver who has a good job (for example, a person who works for it)
The driving posture and driving behavior of each person to meet the requirements of
It is possible to provide a seat that fits. Ma
In addition, the added value of the product can be increased. The upper sheet 2 and the lower sheet 3 are attached to the base 4
It is formed into a corresponding shape. 4 (a) and 4 (b)
As shown in the perspective view, the base 4 provides a seat for the motorcycle 10.
The base part to be configured, with a front stop part 4a,
A raised portion 4b is formed at the center, and the back of the raised portion 4b is formed.
On the side is gold for attaching to the frame of motorcycle 10
The tool 4c is fixed. Also, on the back side of the base 4,
Rubber cushions 4d are fixed at several places (for example, six places).
Is defined. In addition, grooves and holes as shown
Have been. (Manufacturing apparatus and manufacturing method of cushion material 1)
Method) Next, referring to FIGS.
An apparatus and a method for manufacturing the cushioning material 1 will be described.
It should be noted that the method for manufacturing the spring-structured resin molded product 30 is described below.
Will be described later. (1) Input process FIG. 5 illustrates the first stage of the compression molding process of the cushion material 1.
FIG. 6 is a front view for explaining the first stage.
It is a plane sectional view. As shown in the explanatory diagram of FIG. 5 or FIG.
Cavity of female mold 11 made of concrete (hereinafter simply female mold 11)
One or more spring-structured resin molded products 30 are
Put. At this time, two or more spring characteristics are the same or different
The spring-structured resin molded product 30 may be placed at the same time.
As described above, the spring-structured resin molded product 30 has a linear shape.
Three-dimensional structure with voids formed by randomly entangled 31
It is a structure, and this line 31 has a plurality of loops or curls.
(See a partially enlarged view C of FIG. 5). In this manufacturing method, the spring structure tree
The softening point of the raw resin constituting the filament 31 of the resin molded product 30
Since the above temperature is required, the cavity 12 of the female mold 11
As shown by an arrow in the figure, hot water (preferably
Is 70 ° C. or more), and a resin molded product having a spring structure 30
Is heated and softened. The hot water used here is the female mold 1
1 heats the spring-structured resin molded product 30 from inside.
That's why. Also, the female mold 11 itself is heated by a heater or the like.
Is also good. At this time, the heat conductor (for example, heater) is
Preferably, it is embedded in the eleventh concrete.
Cover the periphery of the female mold 11 with heat insulating material to enhance the heat retention effect
It is also preferable (for example, containers made of wood, foamed resin, etc.). Ma
Also, the filament 31 constituting the spring-structured resin molded product 30
Ambient air (including hollow air in the case of hollow wire)
If it is necessary to heat, it is molded with the residual heat of the female mold 11
It is also preferable to do so. In addition, instead of hot water supply device 13,
The heating may be performed by the team supply device 17 or the like. Use steam
If there is, for example, a steam injection hole is formed in the female mold 11
And steam is injected into the cavity 12 from the steam injection hole.
Will be injected. Inject and add steam during the mold clamping stage
Heating is preferred. Then, when the heat becomes uniform
Both are preferred because they can be molded at higher temperatures
No. In addition, components that require pressure as well as heating
There are also shaped articles, but in this case heating and heating by steam
Pressure can be performed. Some shapes cannot be heated mechanically
Therefore, it is possible to cope with complicated shapes by using atmospheric pressure
it can. The female mold 11 is made of an appropriate material such as gypsum.
Mold the product form with the material, turn this form upside down,
Fix the board horizontally below and apply a mold release agent to the formwork and board as appropriate.
Apply, knead the concrete powder with water and drop it on the formwork
It is manufactured by squeezing, hardening, and releasing from the mold.
After the concrete has hardened, turn the mold and plate upside down.
Upon removal, the female mold 11 is completed. At this time, put the formwork
Form a space below the plate, and raise and lower the plate to adjust this space.
The strength, rigidity and thickness of the concrete
Can be adjusted. For example, concrete thickness
When increasing the number, lower the fixing position of the plate. In this way,
Concrete is excellent in moldability, it is kneaded and poured into the mold
The cost of the female mold 11 itself is reduced.
(For example, 1/50 to 1/100 of the conventional mold)
It is possible to manufacture a female mold 11 having a rough shape,
Can be easily duplicated, and the accuracy is also improved. An example
For example, the same size can be measured when the female mold 11 is manufactured. Ma
Also, if it is concrete, it is easy to adjust to the product.
Just like polishing the surface of cushioning material 1
It can be formed smoothly. Furthermore, the formwork pattern
It is enough to be able to take it, for example, apply plastic and fasten the mold
By adding a pattern to the surface from the surface degree of vinyl
Surface processing such as is also possible. In addition, female mold 11 made of concrete
Pressure during molding of the cushion material 1
Tens of thousands of cycles
Can also be used. The weight of the female mold 11 is 50 to 10
0 kg is preferred. The male mold 14 is formed from the base 4 and the male mold stand 14a.
Be composed. The male mold 14 is a pantograph jack 15
Pantograph fixed at multiple points by a fixing tool at the tip
The jack 15 allows the female mold 11 to slide over the cavity 12.
This is for clamping the resin molded product 30 with the pulling structure from above.
is there. Male mold 14 can withstand a pressure of 10 tons or more
Is preferred. In the present embodiment, for one male mold 14,
Plural (for example, three) pantograph jacks 15 are installed.
By increasing the load pressure,
The load is distributed to places (for example, three places). Pantagra
Although the jack 15 may be manually operated, the motor 15a
Automatic operation is also possible by mounting. Pantograph jack
The upper end of the key 15 is fixed to the upper base 18, and the upper base 18 is
19 is fixed to the upper part of the female mold 11. Bread tag
Use of rough jack 15 simplifies equipment
Cost can be reduced, but the pantograph jack
Use hydraulic cylinders or pneumatic cylinders instead of keys 15
It does not matter. The male mold 14 is a part of the product.
It is preferable to use the base 4. Base 4 is male on the back
It is attached by being fitted to the lower surface of the mold base 14a.
You. The upper surface of the male base 14a is pantographed by a fixture.
It is fixed to the jack 15. Thus, part of the product
(Base 4) constitutes a part (male mold 14) of the manufacturing apparatus
Thus, only the female mold 11 needs to be prepared, and the male mold 1
4 does not need to be manufactured separately. Conventionally, urethane foam
For molding dies, male and female molds must be manufactured separately from products
However, in this manufacturing method, the male mold 14 itself is a product.
Since it is a part of
The molding accuracy can be improved. (2) Mold Clamping Process FIG. 7 illustrates the second stage of the compression molding process of the cushion material 1.
FIG. 8 is a front view for explaining the second stage.
It is a plane sectional view. As shown in the explanatory diagram of FIG. 7 or FIG.
The male type 14 (here, the base 4
Press down as shown by the arrow in the figure to close the mold.
I do. Here, the cavity 12 of the female mold 11 is
The size is set to match the size and the stroke can be deep or shallow.
You. In other words, because the mold has enough room,
The thickness of the cushioning material 1 can be varied by adjusting the
Wear. Therefore, the thickness can be changed as much as possible with one mold.
Wear. Also, of course, the density is variable. Thus, male
By making the stroke of the mold 14 variable, even deep drawing shallow drawing
Can be manufactured using only one type of mold.
Sex and rigidity can be changed freely. The effect of the variable stroke is as follows.
The thickness of the material 1 can be adjusted to be thin or thick. Thin
When making a cushioning material 1 that is
Only if you want to make thicker cushioning material 1.
It is only necessary to make the stroke shallow with the same mold. That is,
The thickness of the cushioning material 1 can be controlled. Also dense
The degree, spring characteristics and rigidity can also be controlled. As shown
To reduce the inclination angle (taper) of the side surface of the female mold 11
Cushion in one mold (it is almost vertical in the figure)
The thickness of the material 1 can be easily adjusted. For example, the inclination angle is 1/5
0 to 1/400, preferably 1/100 to 1/300,
Particularly preferably, 1/150 to 1/250 (for example, 1/2)
00). The incline is vertical inward or downward
It may be inclined to any outside. Leaning too inward
And stroke control can be difficult
You. This makes it possible to produce various types of cushioning materials 1 in one mold.
According to the required characteristics of the product. In particular, even for the same product,
The thickness of the cushion material 1 can be arbitrarily selected.
For example, an unspecified number of
It can easily respond to detailed needs. The inside of the thigh
In the area where
May be hard. This provides cushioning and durability
And the like. Generally, since the outer shape is the width on which a person can ride,
Although the thickness is almost the same, the thickness of the cushion
Spending characteristics)
Control the thickness of the cushioning material 1 according to the species
Is required. However, urethane foam
In the case of foaming and molding, only a uniform magnification can be realized
I can't. Also, depending on the degree of drawing such as shallow drawing, deep drawing,
It is necessary to prepare many molds. According to the present manufacturing method,
We can solve the above problems of polyurethane foam properly.
You. (3) Trimming Step FIG. 9 illustrates the third stage of the compression molding step of the cushion material 1.
FIG. As shown in the explanatory view of FIG.
After maintaining the state for a predetermined time, the male cutter 14 is
Burr 32 protruding from the end of male mold 14 following the periphery of
(See the partially enlarged view D in FIG. 9)
Thermally weld the terminals. Conventionally, dimensions are newly measured after molding
As well as trimming, etc. to adjust the shape,
The terminal trimming process was difficult. This way
Trimming is possible easily. In particular, at this stage
By rimming, the terminal will no longer loosen
In addition, there is no need to measure dimensions later,
You. (4) Release process Cooling water is poured into the cavity 12 of the female mold 11 and
The solidified resin article 30 is solidified. Because it cools slowly
Instead of quenching with water
Wear. After the curing time has elapsed, the mold is released. Solidified
Pantograph jack 1
Loosen 5 and if there is no springback, it is solidified
State. Hereinafter, female mold 11 and / or spring structure
The heating and cooling of the resin molded product 30 are repeated. Hollow streaks
The appropriate thermal equilibrium conditions considering the air in the hollow
By doing so, springback can be prevented. At this time, the female mold 11 is made of concrete.
In this case, the raw resin does not melt and adhere to the female mold 11.
No release agent is required. With conventional metal molds, temperature rise
And the difficulty is that the raw resin easily adheres to the mold.
You. Therefore, a release agent is necessary for the production of urethane foam.
It takes time and effort to manufacture. Also,
If it is made of concrete, it is easy to adjust to the product.
Excellent ability to duplicate and mold complex shapes
It is possible. (5) Final Process As shown in the explanatory drawing of FIG.
Upper sheet 2 and lower sheet 3
Put on and fix. Heat-molded vinyl leather
-5 and stop it on the base 4 with a stapler or the like. Double-sided
It may be adhered with a loop or the like. Also, during the forming process, the lower sheet 2
By forming a convex portion (or concave portion) on the base 4,
Fits and fixes into appropriately provided recesses (or protrusions)
This eliminates the need for staples and double-sided tape. In addition,
The sheet 2 and the lower sheet 3 are suitably bonded with an adhesive or a double-sided tape.
It is possible to prevent misalignment by bonding. Same as above
The upper sheet 2 and the lower sheet 3 are provided with irregularities.
The seat 3 can be fitted and fixed. However, the book
In the process, if you put vinyl leather 5 etc.
Without fixing upper sheet 2, lower sheet 3, and base 4 in particular
In some cases, it is okay. (Method of Manufacturing Spring-Structure Resin Molded Product 30)
Method) Next, a method of manufacturing the above-mentioned spring-structured resin molded product 30
An example of the method will be described. As shown in the schematic diagram of FIG.
The spring-structured resin molded product 30 according to the present embodiment
In the production method of the above, preferably, polio such as PE or PP is used.
Refining resin and raw materials such as VAC, EVA or SBS
The resin may be a tumbler, cutout feeder, or
Is dry-blended via a quantitative feeder or mixed
Or, it is pelletized by melt mixing,
0 is sent to the hopper 21. Specifically, raw material resins, for example, PP and S
BS tumbler (Kato Riki Seisakusho KR mixer)
Mix at 40 rpm for 15 minutes. Next, as shown in the perspective view of FIG.
The mixture consisting of the feed resin is supplied to a φ65 m single screw extruder 20.
It is thrown in from the hopper 21 and has a predetermined temperature (for example, 200 ° C.
260 ° C.) and a predetermined diameter provided on the forming die 22
Extrusion at a given extrusion rate from multiple nozzles
Then, by taking over by a take-off machine 23 described later,
Wire diameter (for example, 600 to 90,000 denier,
Or 3,000 to 30,000 denier, more preferred
Or 6,000 to 10,000 denier)
And / or forming a hollow filament 31 and forming the molten filament 3
1, for example, a diameter of 1 to 10 mm, preferably a diameter of 1 to 1
A 5 mm loop is formed, and the adjacent filament 31 and bus 2
5. Random loop by contact entanglement in (underwater)
Form the soup. At this time, at least the contact entanglement site
Preferably, some are fused together. This and
The wire 31 has a predetermined ratio between a hollow one and a solid one.
May be mixed. The three-dimensional structure which is a set of the above random loops
The thickness and bulk density of the structure are determined by the pulling machine 23 in the bus 25.
It is set between the wiping rolls 24, 24. This three-dimensional structure
Body (for example, thickness 10 to 200 mm, width 2,000 m
m) indicates that the filament 31 is randomly curled or looped.
Formed, solidified in water, and taken up on take-up rolls 26, 26
It is taken out as a resin product 30 having a spring structure.
You. Also, this loop is formed in water.
When the stranded wire 31 is taken up by the take-up machine 23, the take-up machine
By changing the speed of No. 23, the cushion characteristics are changed
May be. In that case, the bulk density of this three-dimensional structure
When increasing, 0.03 to 0.08 g / cm ^Three , Preferred
Or 0.04 to 0.07 g / cm ^Three , Especially 0.05
~ 0.06 g / cm ^Three It is preferable that Also,
When decreasing the porosity of the three-dimensional structure of
%, Preferably 92 to 96%, especially 93 to 94%.
Preferably. Further, for example, take-up rolls 24, 24
Set the take-up speed for each set time using a timer, etc.
Set the take-up speed of the take-up machine 23 to a low speed within a certain time.
By adjusting the speed slowly at regular intervals (for example, 3 to 5 m)
In the longitudinal direction of the spring-structured resin molded product 30.
At low speed at predetermined intervals (for example, 30 to 50 cm).
The part with large bulk density formed at the time of
The portion, that is, the density may be continuously formed. As shown in the front view of FIG.
The spring structure resin molded product which is a three-dimensional structure
30 is difficult to be bent by the take-up rolls 24, 24.
In difficult cases, it can be done by making coarse bulk density parts.
You can bend it at the part and pull it out of the water.
Spring structure resin molding taken out through the above process
The article 30 is cut into appropriate lengths by the cutting device 27.
The bus 25 has a water supply valve and a drain valve.
(Not shown). FIG. 14 is a front view showing another example.
As shown, a cutting device 127 is provided in the bus 125.
, The cutting device 127 is disposed near the lower portion of the take-off machine 123,
On the opposite side wall of the bus 125, a single piece cut at the cutting site
Conveyor with a large number of locking projections inserted into the gaps
Transport device 128 comprising About the composition of other parts
Therefore, the above description is referred to as the 100s. According to the above manufacturing method, for example,
Degree 0.03g / cm ^Three , 50mm thick spring structure
A resin molded product 30 was obtained. The three-dimensional structures are
Using a combination of one or more different properties
Can also be manufactured. In addition, by the above manufacturing method
Manufacturing example of molded spring structure resin molded product 30 and
The inventor first opened the experimental results and other details.
Referenced Japanese Patent Application No. 2000-246907 issued
No. (Another example of the spring-structured resin molded product 30)
Embodiment) Next, the spring structure resin molding of the above embodiment.
An example other than the product 30 will be described. Viscous elastic of raw resin
Using various molding methods that take advantage of the
You. The spring-structured resin molded product 30 is
In the manufacturing process of
Arbitrarily create three-dimensional structures with different cushion characteristics for each part
Can be shaped. For example, as shown in FIG.
From the outer periphery to the center, like the ring-shaped resin molded product 130
Cushion characteristics gradually soften at predetermined intervals or gradually
Can be done. Here, the hard portion 130
a and a soft portion 130b at the center.
Also, a spring-structured resin molded product 2 shown in FIG.
Harden the cushioning properties at the center, as in 30
Can also. Here, the hard part 230a and the outer part
A soft portion 230b is formed around the circumference. FIG.
As shown in FIG.
In addition, the cushion characteristics can be partially changed
You. Here, a part of the soft portion 330b is partially hardened.
(For example, two places). For example, a spring-structured resin molded product 130
If so, cushion material for the seat of the motorcycle 10
Is preferred. Harden the sides of the cushioning material 1
When driving with the seat in between,
Fits well to the inner thigh of the bar, improving running stability
You. Moreover, if it is a spring structure resin molded product 230,
It is also suitable as a cushion material for a helmet. like this
The surface (the part in contact with the head) is soft with one three-dimensional structure
Thus, the inside is hard and the hairstyle is hard to collapse
We can also manufacture hats (shade hats, helmets, etc.)
Wear. This allows for awning and good ventilation
It is preferred. Also, depending on the load and the amount of deflection, the cushion
Depending on the material, it is sufficient if only the surface is hard
There is also In such a case, as described above,
In addition to partially changing the density in the structure,
Manufacturing multiple three-dimensional structures and superimposing them in various ways
To form a single resin structure with spring structure
You can also. In this method, the use of raw resin
The amount can be reduced, which is preferable in terms of productivity. For example, figure
16 (a) is a spring-structured resin molded product 430.
Thus, a three-dimensional structure having a low bulk density is provided below the three-dimensional structure 430a.
Body 430b, below which is a three-dimensional structure with lower bulk density
One spring structure tree by overlapping and bonding 430c
A fat molding 430 can be configured. A spring structure shown in FIG.
Like the resin molded product 530, the hole 5
By forming 30a (partition block
Molding) and partial reinforcement. Hole 530 is compressed
It may be formed before molding, or may be formed after compression molding.
You can do it. Also, as shown in FIG.
A stopper 530b such as a metal fitting can be inserted into the 30a.
You. The stopper 530b may be inserted before the compression molding.
Alternatively, it may be inserted at a stage after compression molding. Constructing a resin molded product 30 having a spring structure
The wire diameter of the filament 31 does not necessarily have to be uniform. 1
Depending on the location, the load
It takes differently. To make it harder only in that area
In addition to changing the bulk density, a spring-structured resin molded product
Change the thickness and hardness of the filament 31 itself that constitutes 30
You can also. For example, the load hitting the buttocks is concentrated
For thick areas, use thick wires or wires with high resin hardness
Is preferred. At this time, it is necessary to manufacture a partially thick filament.
For example, as shown in FIG.
Is the diameter of the nozzle port 622a partially (for example, at the center).
Is preferably larger than the normal nozzle port 622b.
New As shown in FIG. 17B, this molding die 622
Then, at the same time as the extruded normal filament 31
A thick filament 631 is extruded (eg, from the center). This
Thereby, the rigidity can be changed in a complex manner. Further, by changing the material of the filament 31,
Soft or hard cushion with the same thickness and bulk density
Material can be formed. For example, motorcycle 10
Weight of the occupant if the cushioning material 1 of the seat is
Various materials can be selected according to the
Can also be obtained. Also, the spring structure resin molded product 30
Is entangled with various things such as fibers and wires and hybrid-molded
be able to. This makes them vulnerable to heat, buckling, for example.
With resin weakness entangled inside
Can be reinforced. For example, FIG.
As shown in FIG.
It is preferable that the wire 733 is entangled with the wire 731.
No. Also, as shown in the cross-sectional views of FIGS.
In addition, the wire 733 and the like not only entangle
It is also preferable to pass through the hollow portion of the wire 731. (Other Embodiment of Cushion Material 1) Female Die 1
1 and male mold 14 to clamp resin structure 30 with spring structure
By changing the heating temperature step by step,
Heat range molding with partial rigidity change
You can also. For example, the cushion shown in FIG.
Like hard material 101, hard portion 101a (play
Shape), and form a soft part 101b upward.
Can be. At this time, the edge portion 101c is heated and hard.
It is preferable to mold it into a plate shape. For example, heating the car
The trimmed edge portion 101c is shaped into a plate when trimming.
Preferably. This edge portion 101c is attached to the base 4.
It can be fitted suitably. The edge portion 101c is
Suddenly, after expanding, hooked on base 4 and restored with elasticity
It is preferable to fit and install
No. With such a structure, the cushion material 101 and the base
It is possible to attach and detach the base 4 without locking such as stapler
You can also. The female mold 11 and the male mold 14 have a spring structure.
When clamping the resin molding 30, the female mold 11 is
Toburn, increase mold temperature and weld surface
Epidermis (skin) molding to harden
You. Like the cushion material 201 shown in FIG.
Melt only the surface of the resin structure 30 with spring structure 2
01a can be formed.
(For example, cover with vinyl leather 5)
Absent. For example, molding of instrument panel resin
Can also be used. In other words, the spring structure in the mold
The surface of the resin molded product 30 is melted to form a grain,
In some cases, the body is formed. Also, the cushion material 1 is prevented from being unraveled.
If it is necessary to stop or waterproof, or protect the material appropriately
Hot-burning to form the epidermis 201a
It is particularly preferred to do so. In the present embodiment, the spring structure resin
The cushion material 1 composed of the shaped article 30 has air permeability.
Therefore, in the later process, vinyl leather 5 etc.
Sometimes it is better not to cover. In this case, FIG.
As in the cushion material 301 shown in FIGS.
Covering the periphery of the resin molded product 30 with a net 306
Compression molding is preferred. The network 306 is a compression component.
Even if it can be put on the cushion material 301 after shaping
No. The net 306 is made of a water-repellent material (for example, plastic
Is preferred. This provides good ventilation
It is especially effective in high humidity areas and seasons.
It is fruitful. Car seats running on sand such as buggy
It is also suitable. Further, the net 306 is the cushion material 30.
In order to prevent unraveling of 1 and protect it properly, in durability
Is also excellent. The mesh density of the mesh 306 is not limited to
Is good. After covering the net 306, vinyl leather
5 may be covered. This is a vehicle that unspecified majority rides
Etc. to prevent foreign objects from entering due to mischief, etc.
It is to stop. (Another embodiment of the mold) The female mold 11 and the male mold 14
The top and bottom arrangement can be reversed. With this configuration
If the weight of the female mold 11 made of concrete replaces the weight
Thus, compression molding can be performed using its own weight. Ma
In addition, as shown in FIG.
It is also preferable to mold with a sheet, metal, FRP or the like. this
If the heavier one is the upper mold (pressing side),
Compression molding can be performed using its own weight. For example, on
The mold is heavy concrete and the lower mold is lightweight concrete.
For example, there is an example in which the upper die is large and the lower die is small.
I can do it. In this embodiment, the mold is fast and evenly clamped.
To use the pantograph jack 15
When clamping the mold by its own weight using gravity,
In some cases, the tag jack 15 becomes unnecessary. example
For example, as shown in the explanatory view of FIG.
Suspended by a balancer 115 made of material, etc.
As shown, the female mold 111 and the male mold 114 are
Can be clamped. Even this configuration is suitable
The stroke can be made variable. The female mold 11 is preferably made of concrete.
I took some trimming, margin, and extended
Rate for existing urethane foam production equipment
If the mold is slightly improved, it will be shown in FIGS.
As such, existing equipment can be utilized. For example, existing
The equipment puts raw material resin (liquid) into the cavity,
Bubble in 211 and upper mold 214
Foam), and put it into a spring-structured resin molded product 30,
Clamping, resin molding of spring structure at the clamp end face of the mold
Trim the terminal part by clamping the product 30
To improve the production equipment specially with concrete.
Even if it is not provided, the cushion material 1 in this embodiment can be obtained.
Can be. The existing equipment molds 211 and 214 are, for example,
It may be a metal such as iron. Mold, concrete, metal
Is preferred, but multiple fibers such as fiber reinforced plastic (FRP)
It may be composed of a synthetic resin material. The molding requirements include air temperature conditions and temperature.
Management is also important. The raw resin softens during molding, but
Not a child-level bond and does not completely melt
Therefore, the air inside the spring-structured resin molded product 30 is
Has been kept as it is. At this time, the temperature of the air and the
The softening temperature needs to be in equilibrium. Therefore,
Even if the temperature suddenly cools from a raised temperature, the air inside
Unless the mold is clamped until the temperature becomes even,
The air expands and springback occurs and molding can be performed.
It is not possible. The spring structure tree according to claim 1
According to the method of manufacturing a cushion material made of a fat molded product,
A spring having the desired physical properties such as load resistance and impact resistance
Cushioning material made of plastic molded product
And mass production is possible. Compression
Since it is a shape, you can freely process individual shapes and sizes.
Can be For complex vibrations such as vertical and horizontal vibrations
In this case, it is also possible to provide bulges on both the front and back sides.
It is possible. In particular, the thickness of the cushion material can be reduced by using one type of mold.
Controllable number of molds
No need to meet various product requirements
is there. Specifically, when used in automobiles and motorcycles, etc.
Suitable for each model (suspension characteristics)
Can be For example, manufacturing thin cushioning materials
In that case, it is only necessary to make the stroke deeper. Conversely, thickness
When manufacturing cushioning materials that are not
Just do it. This allows you to tailor-made
Can respond to product characteristics and unspecified large number of detailed needs
This makes it easier to manufacture a high-value-added cushioning material. Further, the stroke adjustment and
Setting of ring-shaped resin molded product (for example, line thickness, material
Quality, bulk density, porosity, etc.)
Besides, cushion performance can be easily changed. Specifically
While the material of the cushioning material is constant as a whole
Also, by compressing and squeezing, the spring characteristics
The setting of the stiffness and the rigidity can be freely set. For example, cars and cars
Types of motorcycles (eg, for touring, road
Through a complicated process depending on the
Instead, the spring characteristics can be varied. Also, for example, Motokku
For loss, the impact on the buttocks is reduced,
It is also possible to drive while sitting on the
Increase. In addition, compared to the secondary processing of urethane foam,
It is simple, and T which was used at the time of urethane foam production
Since no highly toxic raw materials such as DI are used,
The working environment is good without generating toxic gas. According to the present production method, the thermoplastic resin
Oil container for cooking and plastic film for waste agriculture
Resin such as PE, which is a recycled resin for reuse
While being able to regenerate as a high value-added product,
Cushion material itself made of resin molded product with spring structure
Can be regenerated any number of times by re-melting.
In this way, it is excellent in recyclability and after used
Care is taken not to impose a load on the environment. Also,
Inexpensive manufacturing because cycle resin can be used
It is possible. The spring structure manufactured by the present manufacturing method
Cushion material made of resin molded product is durable and resistant
Excellent durability, less local sinking, bottom
There is no sensation and swinging feeling. Also, when sitting down,
Receives the load evenly over the entire part and distributes the pressure
It is possible to use it for a long time,
The sitting comfort is improved. In this way, urethane foam
There is no unique sitting comfort. The spring structure manufactured by the present manufacturing method
Cushion material made of resin molding has high spring characteristics
Conventionally, the key is placed under the seats of automobiles and motorcycles.
Coil spring installed to prevent back-up
Becomes unnecessary. Therefore, while having a simple structure,
Lowering the center of gravity makes vehicles and motorcycles stable
The performance is improved. The spring structure manufactured by the present manufacturing method
Cushion material made of resin molded product has complete continuous void
Since the structure has, the air permeability is excellent. Follow
And never get stuffy. Also, cool through the cushion material
Air for cooling and heating can be ventilated from the heating duct
Therefore, the air conditioner is equipped on the seats of motorcycles, etc.
You can also. Furthermore, even if it is resistant to water and wet
It is suitable for use as a motorcycle seat.
You. In addition, washing is possible, and drying is quick. As described above, the spring according to the present invention
The method of manufacturing a cushion material made of a resin structure molded article
Cars, motorcycles, bicycles, trains or aircraft
Seats, saddles for riding, chairs, sofas or beds, etc.
A person sits, with or without vibration
Where you sleep, sleep or ride
That can be suitably used as a substitute
Method of producing cushioning material composed of resin molded article having sealing structure
It is suitable. The resin having a spring structure according to the present invention
Embodiment of manufacturing method of cushion material made of molded article
The technical scope of the present invention is not limited to the above.
It can take various forms as long as it belongs to the box. Ma
Further, modifications may be made without departing from the technical concept of the present invention.
It is possible to add changes, etc., those modifications,
Equivalents and the like are also included in the technical scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a cushion material 1 and a base 4; FIGS. 2A and 2B show a cushion material 1 and a base 4;
It is the front view and rear view of FIG. FIG. 3 is a side view of the motorcycle 10 provided with a seat made of the cushion material 1. FIGS. 4A and 4B are perspective views of the base 4 viewed from different angles. FIG. 5 is an explanatory view showing a first stage of a compression molding process of the cushion material 1. FIG. 6 is an explanatory view showing the first stage of the compression molding process of the cushion material 1 from another angle. FIG. 7 is an explanatory view showing a second stage of the compression molding step of the cushion material 1. FIG. 8 is an explanatory view showing a second stage of the compression molding process of the cushion material 1 from another angle. FIG. 9 is an explanatory view showing a third stage of the compression molding step of the cushion material 1. FIG. 10 is an explanatory view showing a process of attaching the cushion material 1 to the base. FIG. 11 is a schematic view illustrating steps of a method for manufacturing a spring-structured resin molded product 30. FIG. 12 is a perspective view illustrating a method for manufacturing a resin article 30 having a spring structure. FIG. 13 is an embodiment showing another method for manufacturing a resin molded product 30 having a spring structure. FIG. 14 is an embodiment showing still another method of manufacturing the resin article 30 having a spring structure. FIGS. 15 (a), (b) and (c) are cross-sectional views showing another embodiment of a resin molded product 30 having a spring structure. FIGS. 16 (a), (b), and (c) are cross-sectional views showing still another embodiment of a resin molded product 30 having a spring structure. FIGS. 17A and 17B are a rear view and a perspective view of a forming die 622. FIGS. 18 (a), (b) and (c) are cross-sectional views showing another embodiment of a resin molded product 30 having a spring structure or a filament 31. [FIG. 19] (a) and (b) are cushions It is sectional drawing which shows the other Example of the material 1. FIGS. 20A and 20B are cross-sectional views showing still another embodiment of the cushioning material 1. FIGS. FIG. 21 is an explanatory view showing another embodiment of the compression molding step of the cushion material 1. 22 (a) and (b) are explanatory views showing an embodiment of a compression molding step of the cushion material 1 using existing equipment. [Description of Signs] 1 Cushion material 2 Upper seat 3 Lower seat 4 Base 5 Vinyl leather 10 Motorcycle 11 Female mold 12 Cavity 13 Hot water supply device 14 Male mold 15 Pantograph jack 16 Heat cutter 20 Extruder 21 Hopper 22 Forming die 23 Pulling machine DESCRIPTION OF SYMBOLS 24 Take-up roll 25 Bus 26 Take-up roll 27 Cutting device 30 Resin molded product with spring structure 31 Wire 32

Continuation of front page    (72) Inventor Maki Shirai             2-26-9 Nishi Gotanda, Shinagawa-ku, Tokyo             In Engineering Co., Ltd. (72) Inventor Yuichiro Nakamura             2-26-9 Nishi Gotanda, Shinagawa-ku, Tokyo             In Engineering Co., Ltd. F term (reference) 3B096 AB07 AD02 AD07

Claims (1)

What is claimed is: 1. A method according to claim 1, wherein: the solid and / or hollow continuous filaments and / or short filaments of random loops or curls adjacent to each other are formed of at least thermoplastic resin. Placing a three-dimensional structure with voids of a predetermined bulk density formed by contact entanglement, heating the female mold and / or the three-dimensional structure under temperature conditions necessary to soften the three-dimensional structure, Clamping the three-dimensional structure with the female mold and the male mold, and hardening the three-dimensional structure by cooling. Further, the female mold has a volume corresponding to the stroke of the male mold when the female mold is deep drawn. A method for producing a cushion material comprising a resin molded product having a spring structure, wherein the cushion material is set.