JPH04105910A - Manufacture of one piece product of sewn outer covering and foam - Google Patents

Abstract

PURPOSE:To contrive an easy and rapid positioning operation of a seam line without suffering impairment to a filling tape by a method wherein a positioning pin is pierced through a seam line of an outer covering to be sewn from its rear side and inserted into the positioning hole of a molding die to secure a sewing line in place and a filling tape is thereafter attached to the sewing part of the outer covering. CONSTITUTION:A number of positioning holes 12 are formed in a row on the molding surface of a lower die 6 along a sewing part of an outer covering 2 to be sewn. The outer covering materials 2a and 2b are sewn together at the overlapped edges thereof and the outer ends thereof are folded back and sewn together to obtain the sewn outer covering 2. A positioning pin 13 is pierced through each of the seams 2c at a plurality of places from the rear side thereof and inserted into the positioning hole 12 on the molding surface, thereby securing the outer covering 12 in place on the lower die 6. A filling tape 14 is attached to the sewn part of the sewn outer covering 2 from its rear side to cover the seam and positioning pin 13, foam resin material is poured on the rear side and an upper die 7 and the lower die 6 are placed together with a base material 4 attached to the upper die. After the expansion and hardening of the resin material, the molding is removed from the die and the positioning pin 13 is removed from the surface of the sewn outer covering 2.

Description

[Detailed description of the invention] (Industrial application field) The present invention relates to a method for manufacturing a sewn skin-integrated foam molded product.

(Prior Art) Some automobile instrument panels and doors are covered with a foamed molded product with a sewn skin as a pad or trim. That is, in the second molded product, a sewn skin made by sewing the edges of two skin materials so that their surfaces contact each other is attached to a mold, and a foamed resin material is injected into the back side of the sewn skin. It is made by foaming. In this case, the sewing skin may be attached to the mold with a meandering sewing line, or the sewing skin may shift due to the foaming pressure of the resin material, resulting in an unexpected sewing line.

On the other hand, in Japanese Utility Model Application Publication No. 6'3-69036,
A technique has been disclosed in which a positioning plate is attached from the back side to the seam allowance of the sewing part of the sewing skin, and this plate is fixed to the base material on the upper die side, thereby positioning the sewing line and injecting and foaming the resin material. There is.

(Problem to be Solved by the Invention) However, in the positioning method using the plate as described above, the plate is buried in the resin foam layer, so the cushioning property of the molded product at the sewn part of the sewing skin is is damaged.

It is also conceivable to hook a positioning pin to the sewn part of the sewing skin from the surface side, insert this positioning pin into the positioning hole of the mold, and remove the positioning pin after foam molding of the resin material. However, the work is troublesome when the positioning pins are caught, and the sealing tape attached to the sewing part from the back side to prevent resin leakage or the positioning pins caught on the seams can be torn during work, resulting in leakage of the resin material. becomes more likely to occur.

(Means for Solving the Problems) The present invention utilizes the seams of the sewing skin to attach positioning pins to the sewing part of the sewing skin from the back side, positioning them in the mold, and positioning them from the surface side of the sewing skin after molding. The above problem is solved by removing the pin.

The specific method is to attach the sewn skin, which is made by sewing the edges of two skin sheaths together with their surfaces in contact with each other, to the mold so that the surface of the sewn skin comes into contact with the molding surface of the mold. A method for producing a foam molded product with a sewn skin by injecting and foaming a foamable resin material onto the back side of the sewn skin, the method comprising: attaching the sewn skin to a portion corresponding to the sewn part of the sewn skin on the molding surface of the mold; A positioning hole is formed in advance, and a positioning pin is passed from the back side of the sewing skin through the seam of the sewing part and inserted into the positioning hole of the mold to position and attach the sewing skin to the mold. fI from the back side to the sewing part! A sealing tape is pasted to cover the stitches and the locating pins, and then a foaming resin material is injected into the back side of the sewing skin to make it foam.After that, after removing the mold, the locating pins are attached from the front side of the sewing skin. It is characterized by the fact that it can be removed.

(Function) In the above manufacturing method, the sewing line is positioned by passing the positioning pin through the seam of the sewing skin from the back side and inserting it into the positioning hole of the mold, so that the sewing skin is aligned with the molding surface of the mold. can be inserted into the seam and into the positioning hole, eliminating the need to hook the positioning pin on the sewing part of the sewing skin in advance, making it easy to position the sewing line using the positioning pin. It can be done easily and quickly.

In addition, since the sealing tape is attached to the sewn portion of the sewing skin after the sewing line is positioned using the positioning pins, the sealing tape will not be damaged by the work of attaching the positioning pins mentioned above. The positioning pin can be reliably held in the mold by pasting the sealing tape, and it is possible to prevent the positioning pin from falling off due to the foaming pressure of the resin material and the resulting shift of the sewing skin. Furthermore, the positioning pins only need to be passed through the seams of the sewing skin, and the positioning pins can be easily removed from the surface side of the sewing skin after molding.

(Effects of the Invention) Therefore, according to the present invention, after positioning the sewing line by inserting the positioning pin into the positioning hole of the mold from the back side of the seam of the sewing skin, the positioning pin is inserted into the sewing part of the sewing skin. Since the sealing tape is pasted, the positioning of the sewing line can be performed easily and quickly without causing damage to the sealing tape, and it also reliably prevents the sewing skin from shifting due to foaming pressure, so that the desired result can be achieved. It is possible to obtain a foamed molded article with a sewn skin integrally having a sewn line shape, and since the positioning pins are removed after molding, the cushioning properties of the molded article are not impaired by the positioning pins.

(Example) Embodiments of the present invention will be described below based on the drawings.

1 and 2 show an instrument panel 1 of an automobile. This example is a method of manufacturing this instrument panel 1. The instrument panel 1 is
It has a sewn skin 2 made by sewing together an upper skin material 2a and a lower skin material 2b made of synthetic resin, cloth, or leather,
The sewing skin 2, the foam layer 3 made of urethane resin material, and the base material 4 are integrally molded.

FIG. 3 shows a manufacturing apparatus 5 for the above-mentioned instrument panel 1.
is shown. That is, in the figure, 6 is a lower mold to which the sewing skin 2 is attached, 7 is an upper mold to which the base material 4 is attached, and 9 is an end portion of the sewing skin 2 on the lower skin material 2b side. It is a slide core. The upper mold 7 is connected to the lower mold 6 by a hinge 11 so as to be openable and closable. On the molding surface of the lower die 6, a large number of positioning holes 12 are formed in a chain along the sewing line of the sewing skin 2 in a region corresponding to the sewing part of the sewing skin 2 as shown in FIG. It is perforated.

The above-mentioned instrument panel 1 is manufactured by the following procedure.

(2) By pressure-molding the upper and lower skin materials, a lower skin material 2a and a lower skin material 2b that follow the shape of the final product are obtained.

■ The edges of the skin materials 2a and 2b are overlapped so that their surfaces are in contact with each other, and in this state, the contact parts are sewn together, and the sewn outer ends are each folded back and sewn in to form the sewn skin 2. obtain.

(2) Slide the slide core 9 to the molding position and align the sewing skin 2 with the molding surfaces of the lower die 6 and the slide core 8.

In this case, the surface of the sewing skin 2 is brought into contact with the molding surface.

■ As shown in FIGS. 3 and 4, positioning pins 13 are attached to each of the stitches 2c at multiple locations on the sewing skin 2 (seams 2c at multiple locations appropriate for positioning the sewing line to the desired line). The sewing skin 2 is positioned and attached to the lower die 6 by passing it through from the back side (upper side) of the sewing skin 2 and inserting it into the positioning hole 2 on the molding surface.

The positioning pin 13 has a tapered pin portion passing through the seam of the sewing skin 2, and a hook portion that engages with the sewn portion of the sewing skin 2 at the head thereof.

■ As shown in Fig. 6, in the sewn part of the sewn skin 2,
Back side seam of sewing skin 2 and the above positioning pin] 3
Attach the mouth-stopping tape] 4 to cover the area.

■ Inject foamable resin 4 into the back side (top side) of the sewing skin 2.

■ Attach the base material 4 to the upper mold 7 and align the upper mold 7 with the lower mold 6.

(2) After the resin material is foamed and hardened, the slide core 9 is slid outward, the upper mold 7 is opened, and the molded product is removed from the mold.

(2) As shown in FIG. 7, remove the positioning pin 13 from the surface side of the sewing skin 2 of the molded product while rotating it.

[Phase] Cut off the unnecessary part of the sewing skin 2 from the molded product,
Complete instrument panel 1.

In the above manufacturing method, the upper and lower skin materials 2a and 2b are pressure-molded in advance into the final product shape in step (2).
The sewing in the step (2) makes it easier to finish the sewing line into the intended shape, and the sewing skin 2 conforms better to the forming surface in the step (2).

Also, in the step (■), the positioning pin 13 allows
The sewing line of the sewing skin 2 is accurately positioned with respect to the lower mold 6. In this case, the insertion of the positioning pin 13 into the seam 2c and the insertion into the positioning hole 12 of the lower mold 6 are performed using the lower mold 6.
Since the positioning pin 13 can be installed from above, the work of installing the positioning pin 13 becomes easy. Moreover, since the sewing skin 2 is pre-formed into the shape of the final product and is along the molding surface of the lower mold 6, the seam 2c of the sewing skin 2 is located at a position that approximately corresponds to the positioning hole 12 of the lower mold 6. Since it is provided, it becomes easy to insert the positioning pin 13 into the positioning hole 2 through the 0th hole 2c.

] 0 Furthermore, since the positioning pin 13 is provided with a hook portion, the sewing skin 2 is prevented from coming off upward from the positioning pin inserted into the positioning hole 12 of the lower die 6.
The positioning of the sewing line is ensured.

In addition, in the process (2), since the seams of the sewing skin 2 are closed by the sealing tape 14, leakage of the injected resin material in the process (2) can be reliably prevented, and the positioning pins 13 are connected to the sealing tape 14. Since the sewing skin 2 is held by the lower die 6 so as not to protrude to the back side (upper side) of the sewing skin 2, the sewing skin 2 is prevented from shifting due to the foaming pressure of the resin side in step (2).

In the above embodiment, the positioning pin 13 having a hook portion is used, but a pin without a hook portion may also be used as the positioning pin. Furthermore, a long rod made of resin is inserted into the positioning hole 12 of the lower die 6 through the seam of the sewing skin 2, and only the part necessary for positioning the sewing skin 2 is cut off and used as a positioning pin. The sewing skin 2 may be positioned by repeating the process sequentially at each positioning location.

[Brief explanation of drawings]

The drawings show embodiments of the present invention, in which Fig. 1 is a perspective view of a sewn skin-integrated foam molded product (instrument panel), Fig. 2 is a sectional view taken along line A-A in Fig. 1, and Fig. 3 is a manufacturing apparatus. 4 is a partially sectional perspective view showing a state in which the positioning pin is inserted into the positioning hole of the lower die through the seam of the sewing skin, FIG. 5 is a sectional view showing the above state, and FIG. 6 is the sewing FIG. 7 is a sectional view showing a state in which a positioning pin is inserted into a positioning hole in a lower mold through a seam in the skin, and FIG. 7 is a sectional view showing a state in which the positioning pin is removed from a molded product. 1...Instrument panel (sewn skin integrated foam molded product) 2...Sewn skin 2a...Top skin material 2b...Lower skin material 2C... ... Seam 3 ... Foam layer 6 ... Lower mold 7 ... Upper mold 12 ... Positioning hole 13 ... Positioning pin 14... Sealing tape ship eight (1 barrel -491). Return Ω Part 5

Claims (1)

[Claims] (1) A sewn skin made of two skin materials sewn together with their surfaces in contact with each other is attached to a mold so that the surface of the sewn skin is in contact with the molding surface of the mold, and the above-mentioned A method of manufacturing a foam molded article with an integrated sewing skin by injecting and foaming a foamable resin material to the back side of the sewing skin, the method comprising: forming a positioning hole in a portion of the molding surface of the mold that corresponds to the sewn portion of the sewing skin; Then, from the back side of the above-mentioned sewing skin, pass the positioning pin through the seam of the sewing part and insert it into the positioning hole of the above-mentioned mold.
The sewing skin is positioned and attached to the mold, and then a sealing tape is applied from the back side to the sewing part of the sewing skin so as to cover the seam and the positioning pin, and then a foaming resin material is injected into the back side of the sewing skin. A method for manufacturing a foam molded article with an integrated sewing skin, characterized in that the locating pin is removed from the surface side of the sewing skin after the mold is removed.