JPS62242510A - Manufacture of laminating resin foaming material - Google Patents

Abstract

PURPOSE:To prepare a laminating resin foaming material consisting of two layers of different characteristics bonded integrally by means of a simultaneous molding by partitioning part of molding space into two spaces, upper and lower, and using a mold for foam molding equipped with a dam plate for injecting different foaming liquids in a separated state. CONSTITUTION:After spreading a releasing agent on the inner wall face of a mold 10, a first resin foaming liquid 28 to prepare a flexible layer 36 is injected into a horizontal wall face 18 positioned almost horizontal at the time of setting the mold. The first resin foaming liquid 18 covers the horizontal wall face 20 and spreads, flows along an inclined backward wall face 20 and flows into a space E partitioned by a dam plate 22. Almost at the same time of said injection, a second resin foaming liquid 30 to prepare a rigid layer 38 is injected into the space D partitioned by the dam plate 22. Then, after closing the upper mold 24, the first and second foaming liquids 28 and 30 are foamed and cured. The thickness of film of the first foaming liquid 28 covering a main wall face 16 is adjusted by varying the position of lower mold 12 and the flexible layer 36 and the rigid layer 38 are formed up.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application The present invention provides two layers of foamed wood 11w with different characteristics! The present invention relates to a method of manufacturing a laminated resin foam in which 4 are integrally joined.

Prior art and its problems Vehicle seats are required to have the performance of providing good static comfort to the occupants, and must have a structure that allows the occupants to maintain their naturally desired posture with the least amount of muscle activity. The structure must not exhibit a body pressure distribution that obstructs circulation and promotes fatigue.Furthermore, the degree of fatigue caused by continuous sitting is also an issue, and the cushioning of the seating area must be is slightly more soft than the excessively soft one (jI!
Fatigue can be reduced by using quality pads.

FIG. 1 shows, as an example, a schematic vertical cross-sectional view of the seating part of an automobile seat, in which a foamed polyurethane pad 03 reinforced with cheesecloth is fixed to a zigzag spring 02 stretched on a frame 01. The entire upper surface is coated with 0 epidermis.
4 is covered. On the other hand, in recent years, zig-zig
Omit spring 02 and use foamed polyurethane band 0
A structure in which only 3 is provided as shown in FIG. 2 has also been adopted.

However, when the pad 03 is made of a single layer of polyurethane foam, it is difficult to satisfy the various characteristics required for the comfort of the seating area. The soft foam may be bonded with a foam that is harder than the soft foam by adhesive, or the hard and soft layers may be laminated and foamed together.

However, with the former method, depending on the type of adhesive used, the foam may melt at the bonding interface and turn into a dense, hard structure, which will only have a negative effect on the ``comfort of wearing''. However, there is a problem that the joining work is troublesome and productivity is hindered.

As for the latter method, as disclosed in Japanese Patent Application Laid-open No. 55-96195@, one of two types of resin foaming liquids to obtain both hard and soft layers is injected into the mold to start foaming, and immediately after that, Inject the other resin foaming liquid and use the difference in specific gravity to sink the latter (the other resin foaming liquid) into the lower layer of the former (one resin foaming liquid), and then proceed with foaming of both resin foaming liquids. Although a method (so-called Milsuf method) is known, it is difficult to appropriately determine the interface position of both the hard and soft layers and the thickness of each layer, resulting in a problem that the quality fluctuates. Additionally, if a pre-foamed urethane mold or slab is laminated and foamed, the foaming liquid will penetrate into the slab and form a hardened layer, which will have a negative impact on the comfort of wearing. It will affect you.

In order to solve this problem, a mold 05 as shown in FIG.
It is possible to use In the mold space of the mold 05, there is a weir plate 08 extending from the corner where the mold walls 06.07 intersect.
A part of the mold space is divided into spaces A and B by the weir plate 08.

In order to carry out foam molding using this mold 05, as shown in FIG. A resin foaming liquid 01G is injected into the hard foam to foam it. Each resin foaming liquid 09.01G is
After the resin foaming liquid 09, 010 starts foaming and expanding along the weir plate 08, the foams formed by the resin foaming liquid 09 and 010 press against each other and are joined together as a whole, and the expansion progresses.

According to this molding method, resin foaming liquid 09. By changing the usage ratio of 010, the layer thickness ratio of the soft resin layer that is the seating surface layer and the hard resin layer that supports it can be set appropriately compared to the Milsuff method, and a comfortable feeling in the car can be obtained. be able to.

However, if soft foam is thinly placed on top of hard foam, v4
Assuming that the amount of pouring of the resin foaming liquid 09 is reduced compared to that of the resin foaming liquid 010 in order to form a layer, the progress of the foaming and expanding resin foaming liquid 09 (see arrow C) is similar to that of the mold v06.
There is a problem in that the soft foam does not spread as intended due to the sliding contact between the foam and the plastic foam, and it is difficult to form a V4 layer resin foam with a uniform layer thickness ratio over the entire surface.

Means for Solving the Problems An object of the present invention is to provide a laminated resin foam in which the layer thickness ratio of the laminated resin foam consisting of two foamed resin layers having different properties can be constantly controlled appropriately within a desired area range. It is in the fish that provides the manufacturing method of.

The purpose of this was to create a foam mold that divides a part of the molding space into upper and lower spaces, and is equipped with a weir plate in the mold hole that allows separate injection of different resin foaming liquids. use,
The first resin foaming liquid is injected into the mold hole of the lower mold and allowed to flow along the main wall surface, wetting the main wall surface over a wide area to form a liquid film, and the second resin foaming liquid is injected into the mold hole of the lower mold. This is achieved by injecting into the upper space defined by the weir plate, forming upper and lower molds, and then foaming and curing both resin foaming liquids.

The specific content of the present invention will be made clear by the following description with reference to the drawings.

Embodiment 1 (see FIGS. 5 to 9) The mold 10 is a pad 32 (see FIGS. 8 and 9) used for the seating part of an automobile seat. However, FIG. -rX
(which is a line cross-sectional view), the lower mold 1
2 and an upper mold 24. Lower mold 12. Upper mold 2
4 are formed with mold holes (cavities) 14 and 26 that define molding spaces, respectively. The mold cavity 14 has a main wall surface 16 formed by a horizontal wall surface 18 and a receding wall surface 20.1. A weir plate 22 in an inclined position is provided on a portion of the retreated wall surface 20 corresponding to the front side of the pad 32, and side groove-like portions 15 corresponding to the raised portions 34 on both sides of the pad 32 are provided.

The weir plate 22 divides a part of the mold cavity 14 into an upper space and a lower space E.

The pad 32 can be obtained using the mold 10 made of II4 according to the following operating procedure. This pad 32 is made up of a soft layer 536 as a seating surface layer, and a hard layer 38 as both sides and a lower layer, and a small interval 40 is formed at the interface between the hard and soft layers at the front side of the seating surface.

This small interval 4G is formed by the weir plate 22.

After applying a mold release agent to the inner wall surface of the mold 10, the first resin foaming liquid 28 for forming the soft layer 36 is injected into the horizontal wall surface 18 (see arrow F) which is almost horizontal when the mold is in a stationary position. . The injected first resin foaming liquid 28 spreads to cover the horizontal wall surface 18 and flows along the inclined receding wall surface 20.
The vehicle enters a space E section defined by a weir plate 22. When injecting, it is preferable to move the liquid injection container appropriately so that the surface of the main wall 1G is wetted with the first resin foaming liquid 28 over a wide area g1.

(2) At the same time as the injection operation of the first resin foaming liquid 28, the second resin foaming liquid 30 for forming the hard layer 38 is injected into the space defined by the weir plate 22.

(2) After the upper mold 24 is closed with respect to the lower mold 12, depending on the case, this is placed in a heating furnace and heated to foam and harden the first and second resin foaming liquids 28 and 30.

By the operations of (1), (2), and (2) above, the soft layer 36 and the hard layer I! are formed with almost the desired layer thickness ratio over the entire seating surface area. A pad 32 having 38 formed thereon can be obtained.

That is, the liquid film thickness of the first resin foaming liquid 28 covering the main wall surface 16 is adjusted by changing the posture of the lower mold 12, and the soft g
3B and hard [H2S].

In this process, unlike the resin foaming liquid 09 in the example shown in FIG. 4, the first resin foaming liquid 28 is foamed not only from the space E but also over the entire main wall surface 16.

Guaranteed by expansion.

Embodiment 2 (see FIGS. 10 to 12) Lower mold 12
A transverse protrusion 16a is formed on the main wall surface 16A of A, and as shown by arrow G, when the first resin foaming liquid 28 is injected into the horizontal wall surface 18A, a liquid film is formed on the horizontal wall surface 18A. After the thickness increases.

The thickness of the liquid film on the retreated wall surface 20A is reduced. Therefore, the soft material 11136A of the obtained pad 32A is thicker on the rear side than on the front side. In the figure, 36a is a recess formed by the protrusion 16a.

By providing the protrusions 16a in this manner, the soft layer 36
The layer thickness ratio between A and the hard layer 38A can be changed depending on the location.

Embodiment 3 (See FIGS. 13 and 12) The pad 32B includes a plurality of small protrusions 36b on the seating surface of the soft layer 363 in a portion near the front side thereof. This small protrusion 3
6b is obtained by forming a plurality of small recesses in the main wall surface of the lower mold, and by variously changing the shape of the recesses, not only the shape and dimensions of the small protrusion 36b can be changed, but also the shape of the small projection 36b can be changed. The degree of the soft layer 36 in the vicinity is also changed. Further, by providing the small protrusions 36b on the seating surface of the pad 32B, it is possible to expect a change in the seating feeling.

Embodiment 4 (see FIGS. 15 to 17) The mold 42 has a lower mold 44. First upper mold 52 and second upper mold 56
Consists of. The lower mold 44 has a degassing chamber 50, and a plurality of small openings 48 communicating with the degassing chamber 50 are formed on the main wall surface 46rA.
is formed.

The seat skin 58 is placed along the main wall surface 46 and the peripheral wall surface of the lower mold 44, and the interior of the degassing chamber 50 is degassed to bring the skin 58 into close contact with the main wall surface 4G. 58 is sandwiched and fixed between the lower mold 44 and the first upper mold 52.

Next, the first resin foaming liquid 28 is injected onto the skin 58 to wet the skin 58 over a wide area, and the first upper mold 52 is
The second resin foaming liquid 30 is injected into the upper space portion defined by the weir plate 54 protruding from. After that, the first upper mold 52
The second upper mold 56 is removed to close the mold 42, and as in the previous embodiment, the first resin foaming liquids 28 and 30 are heated, foamed, and hardened, so that the skin 58 is integrated. Bonded pad 3
2Ce(G can.

According to this method, the a-th resin foaming liquid 28 is foamed while the surface of the skin 58 is wetted with the a-th resin foaming liquid 28! Therefore, the soft layer 36c and the skin 58 are strongly bonded, and no air pockets are formed between the soft layer 36 and the skin 58, so the appearance is very good and the durability of the seat can be expected to be improved.

Effects of the Invention As is clear from the above explanation, the present invention uses a weir plate that divides a part of the molding space into an upper and a lower space, and is capable of injecting different resin foaming liquids in a separated state. Using a foam molding mold provided in the mold hole, the first resin foaming liquid is injected into the mold hole of the lower mold, and is caused to flow along the main wall surface of the lower mold to wet the main wall surface over a wide range. While forming a liquid film, a second resin foaming liquid is injected into the upper space partitioned by the weir plate to form the upper and lower molds, and both resin foaming liquids are foamed and hardened. In order to produce a laminated resin foam, a laminated resin foam in which two layers with different properties are joined together can be obtained by simultaneous foaming molding, and the two different foamed resin layers are combined throughout the entire body. It can be formed with a uniform layer thickness ratio or with a locally varied layer thickness ratio, and a high-quality laminated resin foam with a desired laminated structure can be obtained.

[Brief explanation of drawings]

1 and 2 are longitudinal sectional views showing the seating portion of a known automobile seat, FIG. 3 is a conceptual perspective view of a mold for molding a laminated resin foam according to a reference example, and FIG. 4 is a rigging FIG. 5 is a vertical cross-sectional view showing the state in which the resin foaming liquid is injected into the mold. A side view showing a state in which the foaming liquid is injected, FIG. 6 is a sectional view taken along the line Vl-VI, and FIG. 7 is a mold for molding the laminated resin foam (lower mold).
FIG. 8 is a perspective view of the pad obtained by the mold for molding the laminated resin foam, and FIG.
A line cross-sectional view, FIG. 10 is a cross-sectional view showing a mold for molding a laminated resin foam (lower mold) as another embodiment, and FIG. A perspective view, FIG. 12 is a sectional view taken along the line XI-XI, FIG. 13 is a perspective view of a pad obtained using a mold for molding a laminated resin foam as another embodiment, and FIG. 14 is an xrv-xrv view thereof. Figure 15 is a sectional view showing a mold for molding a vR layer resin base body as another embodiment, and Figure 16 is a cross-sectional view showing a mold for molding a &1 layer resin foam body. The perspective view and FIG. 17 are sectional views taken along the line xvi-xvi. 10...Mold, 12...Lower mold, 14...Mold hole,
DESCRIPTION OF SYMBOLS 15... Spiral part, 16... Main wall surface, 18... Horizontal wall surface, 20... Invading wall surface, 22... Weir plate, 24...
- Upper mold, 26... Mold hole, 28... First resin foaming liquid, 30... Second resin foaming liquid, 32... Pad,
34... Protuberance, 36... Soft layer, 38... [!
quality layer, 40... small interval, 42... mold, 44...
Lower mold, 46...Main wall surface, 48...Small opening, 50.
... Deaeration chamber, 52 ... First upper mold, 54 ... Weir plate,
56...Second upper mold, 58...Skin.

Claims (1)

[Claims] In a method for manufacturing a laminated resin foam in which two foamed resin layers with different properties are joined together, a part of the molding space is divided into an upper and a lower two spaces, Using a foaming mold equipped with a weir plate in its mold hole that allows liquid to be injected in a separated state, the first resin foaming liquid is injected into the mold hole of the lower mold, and the main Flow along the wall surface to wet the main wall surface over a wide area to form a liquid film, and at the same time, inject the second resin foaming liquid into the upper space defined by the weir plate to form the upper and lower molds. After closing, foam both resin foaming liquids,
A method for producing a laminated resin foam, characterized by curing it.