JPH0336006B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION Technical Field The present invention relates to a method of manufacturing an integrally foamed molded product, in which a pad portion is integrally foam-molded with a foam material on the inner surface of a cover member such as a headrest.

BACKGROUND ART Conventionally, for example, when manufacturing a head rest, etc., a head rest cover is blow molded from a parison, and during the blow molding, the upper end of the shaft of a stay is inserted into the parison in advance, and the head rest cover is inserted into the parison after the blow molding. The head rest cover and the pad part are integrated to form a head rest with the stay protruding by molding the pad part by foaming and hardening the foam material filled in the rest cover and fixing the upper end of the shaft of the stay with the pad part. things are being done.
However, in this headrest, when the foam material expands in volume by foaming, the air that was pushed into the cover by foaming near the corners of the cover and the foaming gas that was not captured by the foam material during foaming are removed. This tends to cause the product to stagnate and harden, resulting in the creation of a hollow area where no patch exists, which can significantly reduce the product value.

In order to solve this problem, the present applicant fixedly attached a baffle plate to an axial member such as a stay that was inserted in advance into a cover member to be molded, and the baffle plate forced the foaming flow of the foam material. It was previously proposed (Japanese Patent Application No. 133514/1982) that the cover member should be moved and guided to a corner portion of the cover member. However, in this method of manufacturing an integrally foamed molded product, when forming a parting line near the corner of the cover member where the baffle plate is placed to be clamped by the mold, the cover member is pulled by the clamping clamp of the mold. Since the cover member comes into contact with the baffle plate, there is a risk that the cover member may be scratched and torn by the corner edge of the baffle plate.

DISCLOSURE OF THE INVENTION An object of the present invention is to provide a method for manufacturing an integrally foamed molded product in which the foam flow of a foam material is guided to the corner portion of a cover member without damaging the cover member with a baffle plate. purpose.

That is, in the method for manufacturing an integrally foamed molded product according to the present invention, a baffle plate is loosely fitted and supported on an axis member such as a frame that is inserted in advance into a cover member to be molded, and when the cover member is clamped with the mold. The baffle plate is placed at a distance from the parting line of the mold that clamps the cover member, and the baffle plate is moved to the corner of the cover member by the foaming rising of the foam material that is filled into the cover member after molding in the cover member. By pushing up in the direction and using the baffle plate to guide the foaming flow of the foam material to the corner portion of the cover member, it is possible to reliably form the foam hardening layer of the foam material in the corner portion as well. It is being done.

Embodiments Hereinafter, a detailed description will be given with reference to the drawings.

In the illustrated embodiment, for example, a substantially horseshoe-shaped headrest having a cavity in the center is manufactured as an integrally foamed molded product. In this headrest, a corner portion 3 near a rectangular end surface of a rising portion 3 that projects a stay 2 from a cover member 1 is provided.
Since a gap 4' where no pad part 4 is present is likely to be formed at point a, a baffle plate 5 having a cross-sectional shape corresponding to the rising part 3 is loosely fitted and supported on the axis of the stay 2, and the baffle plate 5 will be described later. As shown in FIG.
(See Figure 2).

As the baffle plate 5, a hard or semi-hard resin plate or a metal plate can be used, or a porous plate material that can be impregnated with a foam material and finally hardened integrally with the patch part can be used. Good too. The baffle plate 5 is provided with collar portions 5a and 5b that protrude upward and downward at the opening portion through which the shaft line member 2 such as a stay is loosely inserted. This functions to maintain the distance from the cover member 1 as the foam material expands. In addition, a plurality of protrusions 5c, 5c, etc. are provided at arbitrary intervals on the periphery of the baffle plate 5, so that when the foam material is raised by pushing up the foam, contact with the cover member 1 is prevented from clogging, and the raising can be easily performed. It is being done. (See Figure 3).

Blow molding can be applied to mold the headrest. The blow molding mold 6
is equipped with split molds 6a and 6b on the left and right, and each split mold 6
It has a base 6c on which a and 6b are placed facing each other. The base 6c is equipped with a valve 7a discharging compressed air in the center, and brackets 7b and 7c are provided on the left and right sides of the valve 7a for erecting the stay 2 integrated with the headrest frame 2a. Slide pin 7 that pushes up the baffle plate 5 to be fitted and supported
d, 7e (see Figure 4).

Using this mold 6, the stay 2 is first supported by the brackets 7b and 7c, and the baffle plate 5, which is loosely fitted and supported in advance on each axis of the stay 2, is placed on the slide pin 7d,
7e, push it up close to the headrest frame 2a. Next, the parison forming the cover member 1 is extruded from the die head into a cylindrical shape with its lower end open, and placed on the base 6c so that the headrest frame 2a and the stay 2 are received inside the parison. After that, the parison is clamped and fixed between the split molds 6a and 6b, and at that time, the lower end of the parison becomes the rising part 3 that projects the stay 2 of the headrest, and the lower end side of the split molds 6a and 6b In order to form a parting line, the baffle plate 5 is kept supported upward by slide pins 7d and 7e in order to separate the baffle plate 5 from the parting line. If the split molds 6a and 6b are clamped in this state, the parison forming the cover member 1 will not come into contact with the baffle plate 5 even if it is displaced due to tension. After the mold 6 is clamped and fixed, compressed air is supplied into the parison from the valve 7a of the base 6c to mold the cover member 1 having a desired three-dimensional shape. Thereafter, the cover member 1 molded into a three-dimensional shape is removed from the mold 6, and the inside is filled with the foam material 8. When filled with the foam material 8, the cover member 1 is inverted so that the stay 2 protrudes upward so that the foam material 8 stays inside the top of the cover member 1 (see Fig. 5). Heat and foam. Along with this heating and foaming, the foam material 8 gradually increases in volume and rises, pushing up and moving the baffle plate 5 located near the headrest frame 2a of the stay 2 upward along the axis of the stay 2 ( (See Figure 6). The baffle plate 5 that is pushed up further rises within the rising portion 3 of the headrest, and when the collar portion 5a comes into contact with the end surface forming the corner portion 3a, the baffle plate 5 stops rising, and the form continues to increase in volume. Baffle plate 5 to prevent foaming flow of material
Pour and guide along the plate surface from the edge to the back side. During the guidance, the foaming flow of the foam material rapidly moves through the gap between the cover member 1 and the edge of the baffle plate 5, so that the foam material is forcibly moved to the corner 3a of the cover member 1 and the foam material is 1
Gas can be diffused from the air vent hole 1a. The overflow that causes this foam material flow is 3 to 5.
The desired overflow can be provided by appropriately setting the area of the baffle plate 5 in accordance with the cross-sectional area of the rising portion 3 (see FIG. 7).

In the above-described embodiment, the baffle plate 5 is inserted in advance when the cover member 1 is molded, but it may be attached to an axial member such as the stay 2 after the cover member 1 is molded. Further, in this embodiment, a head rest having rising portions 3 corresponding to the left and right stays is shown, but the present invention can also be applied to the molding of a head rest having a general trapezoidal shape. In that case, one baffle plate is loosely fitted and supported between the stays, and the foaming flow of the foam material can be moved and guided to each corner of the square. Furthermore, it can be applied not only to the production of headrests but also to the production of various foam molded products, and the baffle plate 5
As the member for loosely fitting and supporting the cover member 1, it is possible to use not only a stay projecting from the cover member 1 but also a frame embedded in the foam material.

In this way, by foaming and hardening the foam material, it is possible to integrally mold the pad portion 4 which is filled throughout the interior of the cover member 1.

Effects of the Invention According to the method for manufacturing an integrally foamed molded product according to the present invention, it is possible to integrally mold a part without a void inside the cover member without damaging the cover member with the baffle plate. Become.

[Brief explanation of drawings]

Fig. 1 is a perspective view showing a headrest as an example of an integrally foamed molded product manufactured by the present invention, Fig. 2 is an explanatory view showing problems in manufacturing the headrest, and Fig. 3 is an explanatory view showing problems in manufacturing the headrest.
The figure is a perspective view of a baffle plate used in the method according to the present invention,
Figure 4 is an explanatory diagram of the mold used in the same method, Figure 5 is an explanatory diagram of the cover member filled with foam material after molding, and Figures 6 and 7 are of the foam material shown in Figure 5. FIG. 3 is a partially enlarged side view showing the foaming flow. 1: Cover member, 2: Axis member such as stay, 3
a: Corner, 5: Baffle plate, 6: Mold, 8: Foam material.

Claims (1)

[Claims] 1. A baffle plate is loosely fitted and supported on an axial member such as a frame that is inserted in advance into a cover member to be molded, and when the cover member is clamped, the baffle plate is inserted from the parting line part that clamps the cover member of the mold. The baffle plate is positioned at a distance and moves upward toward the corner of the cover member as the foam material filled into the cover member expands after the cover member is molded with a mold, and the baffle plate covers the foaming flow of the foam material. A method for manufacturing an integrally foamed molded product, characterized in that the movement is guided to a corner portion of a member.