JPH0312885B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a cushion body used for automobile rear back seats and the like.

2. Description of the Related Art Conventional rear back seats and the like of automobiles have a cushion body 1 as shown in FIGS. 1A and 1B. The cushion body 1 is made of an elastic foam material such as polyurethane foam.
It consists of a main body part 2 and a border part 3. The main body 2 has a substantially rectangular plate shape with a flat front surface 2a and an uneven profile on the back surface 2b, and has semicircular notches 2 on its two short sides.
c, 2c are formed. Also, the edge part 3
is made of a foam material that is slightly harder than the foam material that makes up the main body portion 2, and is formed into a rectangular rod shape with a flat surface. The edge burr portion 3 is aligned so that one end surface 3a thereof is flush with the surface 2a of the main body portion 2, and is bonded with an adhesive such as a rubber adhesive, so that the cross-sectional shape 1
As shown in Figure B, the cushion body 1 is shaped like an inverted L. The cushion body 1 thus formed is attached to a steel frame (not shown), then wrapped in an outer skin (not shown) made of leather, woven fabric, vinyl sheet, etc., and mounted on a rear bag. It becomes a sheet. However, when manufacturing the cushion body 1 using the method described above, it is a matter of course that the manufacturing process is time-consuming. To prevent adhesive from coming into contact with other products and causing them to stick, powder must be applied. When wrapping the cushion body 1 with the outer skin, the adhesive surface had to be pressed by hand to prevent it from peeling off, resulting in poor workability.

The present invention has been made in view of the above circumstances, and aims to provide a method for efficiently manufacturing a cushion body having the above shape in which a main body portion and a border portion are integrated. Cut grooves with a depth of about half the thickness of the plate at positions where the distance from the edge of the plate corresponds to the thickness of the edge portion on one surface and the other surface on the opposite side. Then, while elastically deforming the plate on the outer side of one or both of the kerfs, the two plates are It is characterized by cutting the portion sandwiched between the kerfs.

Hereinafter, the present invention will be explained in detail with reference to the drawings.

2 to 6 show an example of the manufacturing method of the cushion body of the present invention in the order of steps. In the figures, reference numeral 11 is a rectangular plate made of an elastic foam material such as polyurethane foam. It is a manufacturing material. First, a cut groove 13 is provided on one surface 12 of this plate 11.
This cut groove 13 extends in the longitudinal direction of the plate body 11,
and at a certain distance d from the long side of the plate 11,
It is provided continuously from one end of the plate 11 to the other end. Furthermore, one surface 12 of the plate body 11
The other surface 14 facing the surface 12 is also provided with a kerf 15 similar to the kerf 13 provided on the surface 12 at a symmetrical position. The depth of these grooves 13 and 15 is smaller than the thickness of the plate 11, and is generally about 1/2 of the thickness of the plate 11. Further, the distance d between the cut grooves 13, 15 and the long side of the plate 11 corresponds to the thickness of the edge burr 3 described above, so it is usually 10
~50mm, but is not limited to this. These cut grooves 13 and 15 can be easily formed by using, for example, a rotary saw.

Thus, as shown in FIG.
3 and 15 are formed, but for the sake of convenience in the following explanation, the plate body 11 outside the grooves 13 and 15 will be referred to as the ear portion, and the ear portion formed by the groove 13 will be designated by the reference numeral 16.
17 is attached to the ear portion formed by the cut groove 15.

Next, the grooves 13 and 15 of the plate 11 are elastically deformed and pushed open using a guide plate, a guide roller, etc., and the ears 16 and 17 are pushed open outward as shown in FIG. While keeping the ears 16 and 17 pushed open, next press the plate 11.
Cut groove 1 using a regular profile cutter.
Cut along the plane connecting the bottom of No. 3 and the bottom of kerf 15 so that the cut surface becomes a profile (No. 4
figure). The cutting direction during this cutting is the kerf grooves 13, 1.
In addition to cutting in the longitudinal direction of the plate 11 by moving the cutter along the longitudinal direction of the cutter 5, cut grooves 13, 1 are cut in a direction perpendicular to the longitudinal direction of the plate 11, that is, in one direction.
There is also one in which the cutter is moved from 5 to the other kerf 15, 13. Further, cutting with a profile cutter can be performed, for example, by the method described in Japanese Patent Publication No. 31-3544.

Next, the rollers and the like holding down the ears 16 and 17 are removed and the ears 16 and 17 are returned to their original positions to form two cushion bodies that fit into each other as shown in FIG. If these are separated, the main body 18 has an uneven profile surface.
Two desired cushion bodies 20, 20 in which the and edge portions 19 are integrated can be obtained at the same time (sixth
figure).

FIGS. 8 and 9 show the main parts of a specific cutting device for cutting the plate 11 along the plane from the bottom of one kerf 13 to the bottom of the other kerf 15, and its main parts. FIG.

Reference numerals 21 and 22 in the figure indicate a pair of profile roles. This profile roller 2
1 and 22 have numerous columnar protrusions erected on their circumferential surfaces, similar to those used in normal profile cutting, but the columnar protrusions are omitted here for convenience. be. Further, a thin band-shaped band knife 23 is provided between the pair of profile rollers 21 and 22.
This band knife 23 is attached to the profile roller 2
It runs endlessly at high speed in the axial direction of the profile rollers 21 and 22, and slices the plate 11 compressed by the profile rollers 21 and 22.

Further, reference numeral 24 in the figure is a guide plate. This guide plate 24 is composed of a leading plate 25 formed by twisting a rectangular plate member by 90 degrees along its longitudinal direction, and a holding plate 26 extending at right angles from the rear end of this leading plate 25. , the hold plate 26 is attached to the main body of the apparatus by a suitable attachment means, and is held and fixed in the state shown in the figure.

Further, a guide belt 27 is provided near the upper side of the guide plate 24 . This guide belt 27 is connected to a first pulley 28, a second pulley 29 and a presser roller 3 as shown in the figure.
It is designed to run endlessly between zero and zero. The first pulley 28 is provided slightly above the front side of the cutting device, and the second pulley 29
is provided slightly rearward than the profile rollers 21 and 22. In addition, the presser roller 30
is for preventing the guide belt 27 from coming into contact with the upper profile roller 21.
It is provided at a position that presses the guide belt 27 downward. This guide belt 27 is configured to travel in the direction of the arrow in the figure by a drive mechanism (not shown).

Furthermore, the reference numeral 31 in the figure is a belt conveyor that conveys the plate 11 in the direction of the profile rollers 21 and 22.

In addition, on the opposite side of the cutting device, a guide plate 24 and a guide belt 27 having a similar structure, and a first
A pulley 28, a second pulley 29, and a presser roller 30 are provided at symmetrical positions on the back side of the plate 11, but are omitted here.

Next, the cutting method will be explained.

A plate 11 made of an elastic material with cut grooves 13 and 15 formed in advance by a rotary saw or the like is placed on the belt conveyor 31, and the profile roller 2
2, 22. At this time, it goes without saying that the positions of the leading plates 25 of the guide plates 24 are determined so that the leading ends of the guide plates 24 enter the grooves 13 and 15 of the plate body 11.

Eventually, the plate 11 is fed, and the leading plate 25 of the guide plate 24 is inserted into the cut groove 13.
When the tip of the plate 11 is inserted and the plate 11 is sent rearward in this state, the ears 16 of the plate 11 are forcibly and gradually expanded outward along the leading plate 25, and the cut grooves are gradually expanded. 13 is exposed, and the ears 16 lie horizontally. The ears 16 in this horizontally expanded state are conveyed together with the plate 11 between the profile rollers 21 and 22 while being held in this state by the guide belt 27. In this state, the profile roller 2
1 and 22, the plate 11 is compressed, and the band knife 23 runs almost in contact with the surface of the expanded ear 16, thereby slicing the plate 11. Exactly the same operation is performed simultaneously on the other kerf 15 and the ear 17 of the plate 11, and a profile is cut between the bottoms of both kerfs 13 and 15.

After cutting, the deformation of the ears 16 and 17 of the plate body 11 naturally returns to its original state, resulting in a cushion body as shown in FIG. 5.

According to this method of manufacturing a cushion body, in the cushion body 20 obtained, the main body portion 18 and the edge portion 19 are integrated, so there is no need to take the trouble to manufacture the edge portion 3 as in the conventional case. Moreover, there is no need to join the edge burr part 3 to the main body part 2, no adhesive is required, the process can be sent to the next process immediately, the labor of processing can be omitted, and the manufacturing cost can be significantly reduced. Further, since there is no bonded portion, no peeling phenomenon occurs, and the durability of the cushion body 20 itself is improved. moreover,
Two cushion bodies 20 can be obtained at one time, which is efficient.

Alternatively, as shown in FIG. 7, the plate 11 may be cut flat along a surface connecting the bottoms of the grooves 13 and 15 provided in the plate 11. Also, instead of pushing the ears 16, 17 open and pushing the ears 16, 17 outward, the ears 16, 17 are pressed from above or below to elastically deform and crush, and while this state is maintained, The plate body 11 may be cut. Furthermore, in the above embodiment, the kerf 1
Although the depths of the grooves 3 and 15 are the same, the depth is not limited to this, and it is also possible to have different depths to obtain two cushion bodies 20 with different dimensions. Also, depending on the type and format of the cutting cutter, both ears 1
It is also possible to elastically deform only one of 6 and 17 to push it open or to cut it in a crushed state.

As explained above, according to the method for manufacturing a cushion body of the present invention, a cushion body in which the main body portion and the edge portion are integrated can be easily manufactured in a small number of steps, and compared to the conventional method, the cushion body can be manufactured easily. This greatly reduces the time and effort involved, resulting in a significant reduction in manufacturing costs. Furthermore, the resulting cushion body is strong and has improved durability since there is no joint surface. Furthermore, it is very efficient because two cushion bodies can be manufactured at the same time.

[Brief explanation of the drawing]

Fig. 1 shows a cushion body obtained by a conventional manufacturing method, A is a front view, B is a sectional view, and Figs. 2 to 6 are perspective views showing an example of the manufacturing method of the present invention in the order of steps. , FIG. 7 is a perspective view showing another example of the manufacturing method of the present invention, and FIGS. 8 and 9 are perspective views of essential parts showing a specific example of the plate cutting method of the invention. DESCRIPTION OF SYMBOLS 11... Plate body, 12... One surface, 13... Cut groove, 14... The other opposing surface, 15... Cut groove, 20... Cushion body.

Claims (1)

[Claims] 1. A method for manufacturing a cushion material, in which two cushion materials each having an L-shaped cross section and consisting of a main body portion and a border portion are cut from a single plate made of an elastic material. The distance between one surface of the plate and the other surface opposite thereto from the end of the plate corresponds to the thickness of the edge part, and a thickness of about half the thickness of the plate is provided. kerfs of different depths are respectively formed, and then, while elastically deforming the plate on the outside of one or both of the kerfs, along the surface from the bottom of one kerf to the bottom of the other kerf. A method of manufacturing a cushion body, characterized in that a portion of the plate body sandwiched between the two grooves is cut. 2. The method of manufacturing a cushion body according to claim 1, wherein the portion of the plate between the two grooves is cut using a profile cutter.