JPH06312425A - Manufacture of skin integrated foamed article - Google Patents

Abstract

PURPOSE:To form a skin integrated foamed article such as a head rest without sealing an opening which is used to turn the skin inside out or for the insertion of a stay. CONSTITUTION:An opening 6 for the insertion of a stay 3, which is used as well to turn a skin 1 inside out, is formed of two sheets of opening pieces 14 which are confronted to each other and bent inward, and a leg part 5 is made to stick out from a stay hole 7 through the opening 6 by providing the stay hole 7 from which the leg part 5 of the stay 3 is projected to the outside of the skin 1, and an injection hole 8 for a foamed liquid. Then, a fixing part 4 is inserted in the skin 1 from the opening 6, and a fast reacting type foam is injected from the injection hole 8 to form a skin integrated foam article. The opening pieces 14 are pressed by the rapidly swelling foam liquid, are joined tightly and close the opening 6. The stay hole 7 and injection hole 8 are also closed by the fast reaction of the foam liquid.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing small parts such as a headrest and a sun visor, in which the legs of a vehicle stay are exposed, by a skin integral foam molding.

[0002]

2. Description of the Related Art For example, a headrest of an automobile is sewn with several pieces of skin, such as a leather, knit, and cloth, which make up the skin, with the back side facing up. Make a three-dimensional shape. It is manufactured by inserting a stain into the skin, setting it in a foaming mold, pouring a foaming liquid such as urethane foaming liquid, and foaming.

It is necessary to provide an opening in the epidermis when turning over the sewn epidermis and when inserting a station. However, when the foaming liquid is injected, the foaming liquid does not leak to the outside, and the appearance after molding is elegant and the internal pressure is high. And the openings must be sealed to withstand external forces and temperature changes.

From the above point of view, the applicant of the present invention has previously stated that "a method for manufacturing a foam-integrated skin-molded article and an opening holder used for it".
, And applied for a patent (Japanese Patent Laid-Open No. 3-295617).
However, at the present time when cost and manufacturing man-hours are being reduced, the cost of the opening holder and the number of man-hours for using it cannot be ignored.

[0005]

The problem to be solved by the present invention is to solve the problems described above without using the above-mentioned opening holder.
The purpose is to manufacture a foam-integrated molded product such as a headrest with the opening left unsealed.

[0006]

SUMMARY OF THE INVENTION The present invention is to be applied to the manufacture of a skin-integrated molded product having a stationary portion which is built in the molded product and a leg which projects from the molded product. , Its features are as follows.

In other words, two openings are formed by stitching a plurality of epidermis pieces and turning them over, and an opening for inserting the station that also serves as an inside out is bent facing the inside of the epidermis. After being formed of a piece, a leg hole of the station is provided with a step hole projecting outside the epidermis, and a foaming liquid injection hole is provided, and the leg part is projected through the opening part to the outside of the step hole. The fixing part is inserted into the epidermis through the opening, and the high-speed reaction-type foaming liquid is injected through the injection hole to mold.

[0008]

When the high-speed reaction type foaming liquid is injected into the epidermis through the injection hole, the foaming liquid reacts rapidly and expands rapidly. As a result, the two opening pieces are pressed against the expanding foaming liquid to come into close contact with each other to close the opening and prevent leakage. Due to the high-speed reaction of the foaming liquid, leak does not occur in the stem hole and the injection hole.

[0009]

EXAMPLE The present invention will be described with reference to an automobile headrest H, which is a foam-integrated molded article for skin shown in FIG. 5, as an example. Reference numeral 1 denotes a skin, which is made of a leather, knit, cloth or the like lined with a sponge, but the material is not particularly limited. 2 is a cushion formed of a foaming liquid such as urethane foaming liquid. Reference numeral 3 is a stay, which is a fixing portion 4 fixed by a cushion 2.
And the leg portion 5 protruding from the cushion 2 and exposed.

FIG. 2 shows the sutured epidermis 1. Epidermis 1
Is a front skin piece 9, a back skin piece 10, a left skin piece 1
1, a right skin piece 12, and a bottom skin piece 13. 6
Is an opening, 7 is two stem holes, and 8 is an injection hole provided between the steer holes 7.

In order to form the skin 1 as described above, each skin piece 9 to 13 as shown in FIG. 3 is punched out by a press or the like in accordance with the gauge, leaving a seam allowance, or cut by hand cutting. Form. At the same time, the steer hole 7 and the injection port 8 are provided through.

Since the opening 6 is formed when the respective skin pieces 9 to 13 are formed, the opening piece 14 is integrally projected to the front skin piece 9 and the bottom skin piece 13 in the embodiment. The length of both protruding opening pieces 14 is about 30 mm in the embodiment, but may be shorter. It is also possible to provide the opening piece 14 on the rear skin piece 10 and the bottom skin piece 13, and to use the opening piece 14 as a separate member for the front skin piece 9 or the rear skin piece 10 and the bottom. It is also possible to form the side epidermis piece 13 by stitching.

The cut skin pieces 9 to 13 are sewn along the seam 15 shown by the chain line in the figure with the back side, that is, the lined sponge side facing up. 2 to form the opening 6 here
It is also possible to omit the seams 15 'at both ends of the sheet of opening piece 14. When the sewn epidermis 1 is turned inside out through the opening 6, the state shown in FIG. 4 is obtained.

Here, the width L1 of the opening 6 is an interval outside the leg portion 5 of the step-3, that is, an interval outside both the stem holes 7 when the skin 1 has a small expansion and contraction amount such as a velor system. L2
To make it slightly larger and slightly narrower for knit-type materials with a large amount of expansion and contraction, it is possible to turn over the skin 1 and insert a step-3, but prevent the foam liquid from leaking during foaming. . Similarly, the inner diameter of the steer hole 7 is made smaller than the outer diameter of the leg portion 5, and the inner diameter of the injection hole 8 is also set to the funnel 16.
It is smaller than the outer diameter of the locking portion 17 (see FIG. 1).

Next, as shown in FIG. 4, the leg portion 5 of the step 3 to which the foam liquid dispersion member 18 such as slab urethane is attached.
Is passed through the opening 6 from the tip to the stem hole 7 and is then exposed. And after pushing Step-3 until it stops,
The step 3 is reversed and the fixing part 4 of the step 3 is put into the epidermis 1 and the opening piece 14 is pushed into the epidermis 1.

In this way, the skin 1 having the Ste-3 attached thereto
Is a synthetic resin or metal foam mold 19 as shown in FIG.
Then, by inserting the funnel 16 into the injection hole 8 and injecting the high-speed reaction type foaming liquid into the epidermis 1, a headrest H as shown in FIG. 5 is completed.

In the embodiment, the skin piece 9 forming the skin 1
-13 are composed of 6 sheets, but the present invention can be carried out if the number is 2 or more depending on the shape of the headrest H. Further, the present invention can be applied to the manufacture of a skin-integrated foam-molded article such as a sun visor in which the leg portion projects outside the skin.

[0018]

EFFECTS OF THE INVENTION In addition to the steer hole and the injection hole, the opening which doubles as the inside out of the skin and inserts the stem can be foam-molded in an unsealed state, so that the number of steps and cost can be reduced.
Since the leak of the foaming liquid does not occur, no defective product is generated, the finish is clean and the strength is sufficient.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a headrest after completion of foam molding.

FIG. 2 is a perspective view of a skin before foam molding.

FIG. 3 is a plan view of a main part of each epidermis piece before suturing.

FIG. 4 is a front view showing a state in which a stay is attached to a skin before foam molding.

FIG. 5 is a perspective view of a headrest.

[Explanation of symbols]

 1 Epidermis 3 Steering 4 Fixed part 5 Leg part 6 Opening part 14 Opening piece

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Claims (3)

[Claims] 1. In the manufacture of a skin-integrated molded product having a stationary part built into the molded product and a leg consisting of a leg projecting from the molded product, a plurality of skin pieces are sewn together and turned over. The opening for insertion of the station, which also serves as the inside-out of the epidermis, is formed by two opening pieces that can be bent inwardly to the inside of the epidermis, and the legs of the station are outside the epidermis. Providing a projecting stem hole and a foaming liquid injection hole,
After the leg is projected through the opening to the outside of the stay hole, the fixing portion is inserted into the epidermis from the opening, and the high-speed reaction type foaming liquid is injected from the injection hole to form the molding. A method for producing a foam-molded product integrated with a skin. 2. The method for producing a skin-integrated foam-molded article according to claim 1, wherein both ends of the opening are sewn together. 3. The method for producing a skin-integrated foam-molded article according to claim 1, wherein both ends of the opening are not sewn together.