Foam molded product with skin and method for manufacturing foam molded product with skin

Abstract

To prevent gas accumulation near the inner tongue piece of a bag-shaped skin material.SOLUTION: A foam molded product with skin comprises a bag-shaped skin material covering a foam molded body, from which a pair of tongue pieces protrude inwardly and overlap each other, where a raw material inlet for the foam molded body is provided between the pair of tongue pieces. At least one of the pair of tongue pieces is provided, at the tip side rather than at its base, with a penetration part through the tongue piece.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present disclosure relates to a skinned foam-molded product in which a foam-molded body is covered with a bag-shaped skin material. [Background technology]

[0002] A known conventional skinned foam-molded product is formed by injecting raw material for a foam molded body between a pair of overlapping tongue pieces that protrude inward from a bag-shaped skin material and foaming them (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2014-136397 A (paragraphs

[0022] to

[0023] , Figure 4, etc.) Summary of the Invention [Problem to be solved by the invention]

[0004] In the above-mentioned conventional foam-molded product with skin, there is a problem that gas tends to accumulate near the inner tongue of the bag-shaped skin material. [Means for solving the problem]

[0005] One aspect of the invention is a skinned foam-molded product in which a pair of overlapping tongues protrude inward from a bag-shaped skin material covering a foam-molded product, and an injection port for the raw material of the foam-molded product is provided between the pair of tongues, and at least one of the pair of tongues has a penetration portion that is provided closer to the tip than the base of the tongue and penetrates the tongue. [Brief description of the drawings]

[0006] [Figure 1] FIG. 1 is a side cross-sectional view of a foam-molded product with a skin according to a first embodiment. [Diagram 2] FIG. 2 is a bottom perspective view of the bag-shaped covering material. [Diagram 3] FIG. 3A is a bottom perspective view of an injection port and a pair of tongue pieces provided at the boundary between the skin pieces, and FIG. 3B is an top perspective view of the injection port and a pair of tongue pieces provided at the boundary between the skin pieces. [Figure 4] FIG. 4A is a planar cross-sectional view of a pair of tongue pieces of a bag-shaped skin material, and FIG. 4B is a planar cross-sectional view of the pair of tongue pieces when a foam molded body is foam-molded in the bag-shaped skin material to form a through-hole. [Diagram 5] FIG. 5A is a top perspective view of a pair of tongue pieces according to another example, and FIG. 5B is a plan sectional view of the pair of tongue pieces according to another example. [Figure 6] FIG. 6 is a side cross-sectional view of a bag-shaped skin material set in a foam molding die in an open state. [Figure 7] FIG. 7 is a side cross-sectional view of a bag-shaped skin material set in a foam molding die in a closed state. [Figure 8] FIG. 8 is a cross-sectional side view of a foam molded product foamed in a bag-shaped skin material. [Figure 9] FIG. 9 is an enlarged cross-sectional side view of the vicinity of the penetration part of the bag-shaped covering material. [Figure 10] FIG. 10A is a top perspective view of a through-hole of a skin-attached foam-molded product according to another embodiment, and FIG. 10B is a top perspective view of a through-hole of a skin-attached foam-molded product according to another embodiment. [Figure 11] FIG. 11A is a top perspective view of a through-hole of a foam-molded product with a skin according to another embodiment, and FIG. 11B is a top perspective view of a through-hole of a foam-molded product with a skin according to another embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] [First embodiment] As shown in Fig. 1, a skin-attached foam-molded product 10 according to the first embodiment is used as a headrest for a seat 90 for a vehicle (for example, a car). The skin-attached foam-molded product 10 has a configuration in which a foam molded body 15 is covered from the outside with a bag-shaped skin material 20. Specifically, in this embodiment, the skin-attached foam-molded product 10 is formed by foam molding the foam molded body 15 within the bag-shaped skin material 20 and integrating it with the skin material 20.

[0008] In this embodiment, the bag-shaped skin material 20 is a sewn product formed by sewing together a plurality of skin pieces 21. The bag-shaped skin material 20 is formed with an opening 17K (see FIG. 2) for projecting the leg portion 12A of the stay 12 for attaching the headrest to the backrest portion 91 of the seat 90, and also with an injection port 20K through which the raw material 35 of the foam molded body 15 is injected when the foam molded body 15 is molded. The stay 12 includes a pair of legs 12A aligned in the left-right direction (vehicle width direction) and a connecting portion 12B connecting the upper ends of the legs 12A. For example, the connecting portion 12B is a portion of the stay 12 bent forward from the leg portion 12A.

[0009] In this embodiment, the skin pieces 21 are sewn together at their edges 25 such that the surface sides of the skin pieces 21 exposed to the outside of the skin-covered foam molded product 10 are overlapped. As shown in Figs. 3A and 3B, the sewn skin pieces 21 are folded opposite each other at the stitching (seams 22), and the overlapped edges 25 of the skin pieces 21 (i.e., the seam allowance) protrude inside the bag-shaped skin material 20. The overlapped edges 25 include a pair of tongue pieces 27 that are not sewn together and form the injection port 20K that communicates between the inside and outside of the bag-shaped skin material 20. For example, the pair of tongue pieces 27 protrude more toward the inside of the bag-shaped skin material 20 at the overlapped edges 25 of the skin pieces 21 than at other parts (see Fig. 3B). In this embodiment, for example, one injection port 20K is provided, which opens, for example, on the lower surface of the bag-shaped skin material 20 (see FIG. 2).

[0010] In this embodiment, the boundary between the skin pieces 21 that form the injection port 20K therebetween extends in the left-right direction, and the pair of tongue pieces 27 face each other in the front-rear direction (see FIG. 1). For example, in the skinned foam-molded product 10, the injection port 20K is closed by pressing the pair of tongue pieces 27 against each other by the foam molded body 15. FIG. 2 shows the bag-shaped skin material 20 with the injection port 20K in an expanded state. In this embodiment, only both ends in the left-right direction of the pair of tongue pieces 27 are sewn together (see FIG. 2). The injection port 20K is formed between the non-sewn portions of the pair of tongue pieces 27 (the central portions in the left-right direction of the pair of tongue pieces 27 in the example shown in FIG. 2).

[0011] The bag-shaped skin material 20 may have a laminated structure or a single-layer structure. An example of a laminated structure is one having an artificial leather layer (e.g., one containing polyvinyl chloride resin as a main component) as the outermost layer, and one having a layer of the same type of resin as the foamed body 15 (e.g., polyurethane resin) as the innermost layer. By forming the innermost layer in this way, it becomes possible to easily bond the foamed body 15 and the bag-shaped skin material 20 to each other.

[0012] The foam molded body 15 may be a foam of a thermosetting resin or a foam of a thermoplastic resin. In the example of the present embodiment, the foam molded body 15 is a foam of a polyurethane resin, but may be a foam of a rubber, a foam of a phenolic resin, or a foam of a polyolefin resin such as a polyethylene resin or a polypropylene resin.

[0013] As shown in Figs. 3B and 4A, the skinned foam molded product 10 of this embodiment has a through-hole 30 that penetrates at least one of the pair of tongue pieces 27. In the example of this embodiment, the through-hole 30 is provided in only one of the pair of tongue pieces 27. The through-hole 30 may be provided in either of the tongue pieces 27. Note that, as shown in Figs. 5A and 5B, the through-hole 30 may be provided in both tongue pieces 27. In this case, it is preferable that the through-holes 30 are provided at positions shifted in the pair of tongue pieces 27 so as not to overlap each other. Note that a plurality of through-holes 30 may be provided in at least one of the tongue pieces 27.

[0014] As shown in FIG. 4B, in this embodiment, the raw material 35 of the foamed molded body 15 passes through the through-hole 30 and is foamed and cured to form the through-hole resin portion 18. The through-hole resin portion 18 bonds the pair of tongue pieces 27 together. This makes it possible to make it difficult to open the mouth of the through-hole 30. In addition, when the through-hole 30 is provided in one tongue piece 27, the through-hole 30 is not provided in the other tongue piece 27 at a position that overlaps with the through-hole 30 of the one tongue piece 27, so that the through-hole resin portion 18 can be blocked by the other tongue piece 27. This makes it possible to prevent the through-hole resin portion 18 from jumping out of the bag-shaped skin material 20 from the injection port 20K.

[0015] In the example of this embodiment, the through portion 30 is a cut that reaches the tip of the tongue piece 27 from the base portion 28 side of the tongue piece 27, and is, for example, linear. The through portion 30 may extend in the protruding direction of the tongue piece 27, or may extend in a direction inclined with respect to the protruding direction (see FIG. 11B). As shown in FIGS. 3A and 3B, the base portion 28 of the tongue piece 27 is a root portion located at a bent corner portion of the skin piece 21 of the tongue piece 27, and the through portion 30 is provided on the tip side of the tongue piece 27 relative to the base portion 28 (i.e., the protruding tip side of the tongue piece 27). In the example of this embodiment, the through portion 30 can be formed by making a cut from the tip of the tongue piece 27, so that the formation of the through portion 30 can be facilitated. In addition, since the through portion 30 is provided on the tip side of the tongue piece 27 relative to the base portion 28, it is possible to prevent the through resin portion 18 from protruding outward from the base portion 28.

[0016] The skinned foam molded product 10 of this embodiment is manufactured, for example, as follows. First, as shown in FIG. 2, a bag-shaped skin material 20 is prepared by sewing together a plurality of skin pieces 21. As described above, the bag-shaped skin material 20 is provided with an injection port 20K for injecting the raw material 35 of the foam molded body 15 between a pair of tongue pieces 27, and an opening 17K for inserting the leg portion 12A of the stay 12. In addition, one of the tongue pieces 27 of the skin pieces 21 that form the injection port 20K therebetween has a through-hole 30 that penetrates the tongue piece 27 (see FIG. 3B). The bag-shaped skin material 20 is obtained by turning over a sewn product obtained by sewing together the skin pieces 21 so that their back sides face outward (i.e., so that the edge portion 25 including the tongue pieces 27 protrudes outward), using the injection port 20K as a turning port. As a result, in the bag-shaped skin material 20 , the front side of the skin piece 21 faces outward, and the edge portion 25 including the tongue piece 27 protrudes to the inside of the bag-shaped skin material 20 .

[0017] Once the bag-shaped skin material 20 is obtained, the bag-shaped skin material 20 and the stay 12 are then set in the foam molding die 30 (see FIG. 6). At this time, the bag-shaped skin material 20 is positioned so that the injection port 20K faces upward. The stay 12 is set with the leg portion 12A inserted into the opening 17K of the bag-shaped skin material 20.

[0018] 6, the foam molding die 30 is a known die used for skin-integrated foam molding, and in this embodiment, the first lower die 31 and the second lower die 32 rotatable relative to the first lower die 31 are arranged side by side, and the first upper die 33 and the second upper die 34 are rotatably provided above the first lower die 31 and the second lower die 32. The second lower die 32 and the second upper die 34 are provided with molding surfaces for molding the front portion of the skin-attached foam-molded product 10, and the first lower die 31 and the first upper die 33 are provided with molding surfaces for molding the rear portion of the skin-attached foam-molded product 10. When the bag-shaped skin material 20 is set in the foam molding die 30, the injection port 20K (i.e., the pair of tongue pieces 27) of the bag-shaped skin material 20 is preferably located near the boundary between the first upper die 33 and the second upper die 34. This allows the gas inside the bag-shaped skin material 20 to easily escape through the injection port 20K, as described below.

[0019] Next, raw material 35 of the foam molded body 15 is injected into the bag-shaped skin material 20 through the injection port 20K between the pair of tongue pieces 27 of the bag-shaped skin material 20. For example, a nozzle 36 is inserted into the injection port 20K, and the raw material 35 is injected into the bag-shaped skin material 20 through the nozzle 36. For example, the first upper die 33 is opened so that the raw material 35 of the foam molded body 15 (for example, raw material of a polyurethane resin foam) can be injected into the bag-shaped skin material 20.

[0020] 7, when the raw material 35 is injected into the bag-shaped skin material 20, the first upper die 33 is closed to close the foam molding die 30. Then, for example, the foam molding die 30 is tilted so that the front side of the bag-shaped skin material 20 is lowered. This adjustment of the tilt also makes it possible to prevent gas from being trapped near the tongue piece 27. For example, the side to which the foam molding die 30 is tilted can be determined depending on the position where gas is likely to be trapped.

[0021] As shown in Fig. 8, the raw material 35 is foamed and cured, whereby the foam molded body 15 is foam-molded and integrated with the bag-shaped skin material 20. Then, the integrated foam molded body 15 and the bag-shaped skin material 20 are removed from the foam molding die 30, and the bag-type foam molded product 10 shown in Fig. 1 is obtained.

[0022] Here, when foam molding is performed inside the bag-shaped skin material 20 in this manner, it is conceivable that gas such as air may accumulate inside the bag-shaped skin material 20. When the injection port 20K of the raw material 35 faces upward, as in the bag-shaped skin material 20 of this embodiment, and the raw material 35 foams from below, gas that cannot escape to the outside may accumulate near the tongue piece 27 on the inside of the bag-shaped skin material 20 (for example, at a position facing the tongue piece 27).

[0023] In contrast, as shown in FIG. 9, in the present embodiment, the tongue pieces 27 (at least one of the tongue pieces 27) are provided with the through-holes 30, so that the foaming gas and air can be discharged from the injection port 20K to the outside of the bag-shaped skin material 20. That is, the through-holes 30 function as a gas vent that allows the passage of gases such as foaming gas and air. In this manner, in the present embodiment, the provision of the through-holes 30 in the tongue pieces 27 makes it possible to suppress the occurrence of gas accumulation in the bag-shaped skin material 20. In addition, since gas accumulation is less likely to occur near the tongue pieces 27, it is possible to make it easier for the foam molded body 15 to press the pair of tongue pieces 27 against each other, and it is possible to make it difficult to open the injection port 20K. The gas discharged outside the bag-shaped skin material 20 is discharged outside the foam molding die 30, for example, from the boundary between the first upper die 33 and the second upper die 34.

[0024] Here, by providing the tongue piece 27 with the through-hole 30, gas in the bag-shaped skin material 20 can be easily released, while the raw material 35 of the foam molded body 15 may leak out from the through-hole 30. In contrast, in this embodiment, as shown in the change from FIG. 4A to FIG. 4B, one of the pair of tongue pieces 27 is overlapped with the other tongue piece 27 having the through-hole 30, so that even if the raw material 35 passes through the through-hole 30, it can be stopped by the other tongue piece 27. This makes it possible to prevent the through-hole resin part 18 from leaking out from the injection port 20K (i.e., the base part 28) and to prevent the appearance of the skin-attached foam molded product 10 from being deteriorated. In addition, the raw material 35 that passes through the through-hole 30 and reaches the other tongue piece 27 is foamed and cured to form the through-hole resin part 18, so that the pair of tongue pieces 27 can be bonded together. This makes it possible to make it difficult to open the mouth of the through-hole 30, and also makes it possible to make the injection port 20K between the pair of tongue pieces 27 difficult to open.

[0025] As described above, in this embodiment, the through-holes 30 can prevent gas from accumulating inside the pouch-shaped skin material 20, and can also prevent resin from leaking out of the pouch-shaped skin material 20. As a result, it is possible to improve the productivity of the skin-attached foam molded product 10. Furthermore, this embodiment provides a new technology related to a skin-attached foam molded product, a manufacturing method thereof, and a pouch-shaped skin material.

[0026] [Other embodiments] The skin-attached foam molded product 10 is not limited to a headrest of a seat, but may be, for example, an armrest of a seat. The seat may be for a vehicle (for example, a car) or for a building.

[0027] The shape of the through portion 30 is not limited to that of the above embodiment. For example, the through portion 30 may extend from the tip of the tongue piece 27 toward the base portion 28 and then bend so as to extend in the width direction of the tongue piece 27 (see FIG. 10A). The through portion 30 may extend in the width direction of the tongue piece 27 (for example, between both ends of the tongue piece 27 in the width direction) (see FIG. 10B). The through portion 30 may not be a notch, and may be, for example, a hole. In this case, the through portion 30 may be, for example, a round hole or a long hole (for example, a slit). The through portion 30 may be a shape cut out from the end of the tongue piece 27 (for example, the protruding tip). For example, such a cutout shape may be a semicircular shape or a triangular shape (see FIG. 11A).

[0028] In the above embodiment, the bag-shaped skin material 20 does not have to be a sewn product in which a plurality of skin pieces 21 are sewn together, but may be a product in which a plurality of skin pieces 21 are joined together (for example, by welding or heat sealing). Furthermore, the bag-shaped skin material 20 does not have to be composed of a plurality of skin pieces 21, but may be a resin molded product molded into a bag shape. Even in these cases, it is sufficient to provide a pair of overlapping tongue pieces 27 that protrude inside the bag-shaped skin material 20, and to provide an injection port 20K between the pair of tongue pieces 27.

[0029] <Additional Notes> The following describes the feature groups extracted from the above-described embodiments, while indicating their effects, etc., as necessary. Note that, in the following, for ease of understanding, the corresponding configurations in the above-described embodiments are appropriately indicated in parentheses, but these feature groups are not limited to the specific configurations indicated in parentheses.

[0030] For example, the following group of features of the present disclosure can be considered to have been conceived in relation to "a skinned foam-molded product in which a foam-molded body is covered with a bag-shaped skin material" and "bag-shaped skin material" in response to the problem that "a problem is thought to be that in the above-mentioned conventional skinned foam-molded product, gas accumulation is likely to occur near the inner tongue of the bag-shaped skin material" in the background art of "a conventional skinned foam-molded product is known, which is formed by injecting raw material for a foam-molded body between a pair of overlapping tongue pieces that protrude inward from a bag-shaped skin material and foaming it (see, for example, JP 2014-136397 A (paragraphs

[0022] to

[0023] , FIG. 4, etc.))." Furthermore, there has been a demand for the development of new technologies related to skinned foam-molded products, their manufacturing methods, and bag-shaped skin materials.

[0031] [Feature 1] A skinned foam-molded product, comprising a pair of tongue pieces that extend inward from a bag-shaped skin material that covers a foam-molded body and overlap each other, and an injection port for a raw material of the foam-molded body is provided between the pair of tongue pieces, A skinned foam molded product having a through-portion that is provided on at least one of the pair of tongues and is located closer to the tip than the base of the tongue and passes through the tongue.

[0032] [Feature 2] 2. The skinned foam molded product according to Feature 1, wherein the through-holes are provided in the pair of tongue pieces at offset positions so as not to overlap each other, or are provided in only one of the tongue pieces.

[0033] [Feature 3] 3. The skinned foam molded product according to claim 1, wherein the through-hole is a slit that reaches the tip of the tongue.

[0034] [Feature 4] 4. The skinned foam molded product according to claim 1, wherein the raw material passing through the through-hole foams and hardens to bond the pair of tongue pieces together.

[0035] [Feature 5] A method for producing a skinned foam-molded product by injecting a foaming raw material (raw material 35) into a bag-shaped skin material through a gap between a pair of overlapping tongue pieces that protrude inward from the bag-shaped skin material to foam-mold a foamed molded product, comprising the steps of: A gas vent portion (through portion 30) is provided through at least one of the pair of tongue pieces, The method for producing a skinned foam-molded product comprises discharging foaming gas to the outside of the bag-shaped skin material through the gas vent.

[0036] [Feature 6] A bag-shaped skin material that covers a foam molded body and has a pair of overlapping tongues that extend inward, with the space between the pair of tongues serving as an injection port for a raw material of the foam molded body, The bag-shaped covering material has a through-portion that is provided on at least one of the pair of tongues closer to the tip than the base of the tongue and passes through the tongue.

[0037] According to the above-mentioned features, it is possible to make it more difficult for gas to accumulate near the inner tongue of the bag-shaped skin material than in the past. In addition, according to the above-mentioned features, a new technology relating to a skin-attached foam-molded product, a manufacturing method thereof, and a bag-shaped skin material is provided.

[0038] In addition, although this specification and drawings disclose specific examples of the technology included in the scope of the claims, the technology described in the claims is not limited to these specific examples, but includes various modifications and variations of the specific examples, as well as parts of the specific examples taken alone. [Explanation of symbols]

[0039] 10. Foam molded products with skin 15 Foam molding 20 Bag-shaped skin material 20K inlet 27 Tongue piece 28 Base 30 Penetration 35 Raw materials

Claims

1. A skinned foam-molded product, comprising a pair of tongue pieces that extend inwardly from a bag-shaped skin material that covers a foam-molded body and overlap each other, and an injection port for a raw material of the foam-molded body is provided between the pair of tongue pieces, A skinned foam molded product having a through-portion that is provided on at least one of the pair of tongues and is located closer to the tip than the base of the tongue and passes through the tongue.

2. 2. The skinned foam molded product according to claim 1, wherein the through-holes are provided at positions offset from one another on the pair of tongue pieces so as not to overlap each other, or are provided on only one of the tongue pieces.

3. 2. The skinned foam molded product according to claim 1, wherein the through-hole is a notch that reaches a tip of the tongue.

4. 2. The skinned foam molded product according to claim 1, wherein the raw material passing through the through-hole is foamed and hardened to bond the pair of tongue pieces together.

5. A method for producing a skinned foam-molded product by injecting a foaming raw material into a bag-shaped skin material through a gap between a pair of overlapping tongue pieces that protrude inward from the bag-shaped skin material to foam-mold a foamed molded product, comprising the steps of: A gas vent is provided penetrating at least one of the pair of tongue pieces, The method for producing a skinned foam-molded product comprises discharging foaming gas to the outside of the bag-shaped skin material through the gas vent.

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