Bag-shaped skin material and skinned foam-molded product

Abstract

To disclose a technique for improving the appearance of an injection portion in a skinned foam-molded product in which a foam-molded body is molded inside a bag-shaped skin material.SOLUTION: One aspect of the invention is a bag-shaped skin material in which partial edge portions of skin pieces sewn together into a bag shape are overlapped to form a pair of protruding pieces protruding inwardly of the bag shape, and a foaming resin raw material injection portion that is not sewn to each other is provided midway in the width direction of the pair of protruding pieces. the bag-shaped skin material includes edge sewn portions where ends in the width direction of the pair of protruding pieces are sewn to the skin pieces in a fallen state; and a cut portion formed on one of the protruding pieces in the width direction between the foaming resin raw material injection portion and the edge sewn portion and obtained by cutting the protruding piece from its tip.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure relates to a bag-shaped skin material and a foamed molded article with a skin.

Background Art

[0002] As a conventional bag-shaped skin material, a pair of projecting pieces are formed by overlapping the edges of the skin material sewn into a bag shape and projecting inward, and an injection part for a foamed resin raw material is provided at a portion where the projecting pieces are not sewn together (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Disclosed is a technique capable of improving the appearance of an injection part in a foamed molded article with a skin in which a foamed molded body is molded inside a bag-shaped skin material.

Means for Solving the Problems

[0005] One aspect of the invention is a bag-shaped skin material in which a pair of projecting pieces are formed by overlapping the edges of a part of a skin piece sewn into a bag shape and projecting inside the bag shape, and a foamed resin raw material injection part not sewn together is provided in the middle of the pair of projecting pieces in the width direction, wherein the end portions of the pair of projecting pieces in the width direction are edge sewing portions sewn to the skin piece in a fallen state, and a cut portion formed by cutting the projecting piece from the tip between the foamed resin raw material injection part and the edge sewing portion in the width direction of one of the projecting pieces, and the bag-shaped skin material includes the cut portion.

Brief Description of the Drawings

[0006]

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DETAILED DESCRIPTION OF THE INVENTION

[0007] [First Embodiment] As shown in FIG. 1, the foamed molded article 10 with skin according to the first embodiment is used as a headrest of a seat 90 for a vehicle (for example, a car). The foamed molded article 10 with skin has a configuration in which a foamed molded body 15 is covered with a bag-shaped skin material 20 from the outside. Specifically, in the example of the present embodiment, the foamed molded article 10 with skin is obtained by foaming and molding the foamed molded body 15 inside the bag-shaped skin material 20 and integrating it with the skin material 20.

[0008] In the example of the present embodiment, the bag-shaped skin material 20 is a sewn product formed by sewing a plurality of skin pieces 21 together. The bag-shaped skin material 20 is formed with an opening 17K (see FIG. 3) for protruding the leg portion 12A of the stay 12 for attaching the headrest to the backrest portion 91 of the seat 90, and a raw material injection portion 20K into which the raw material G of the foamed molded body 15 is injected during the molding of the foamed molded body 15. The stay 12 includes a pair of leg portions 12A arranged in the left-right direction (vehicle width direction) and a connecting portion 12B connecting the upper ends of these leg portions 12A. For example, the connecting portion 12B is a portion bent forward from the leg portion 12A of the stay 12.

[0009] In the example of the present embodiment, the skin pieces 21 are sewn together at their edges 25 such that the front surfaces of the skin pieces 21 that are exposed outside the foamed molded article 10 with skin overlap each other (see FIG. 2). The sewn skin pieces 21 are bent in opposite directions at their sewing portions (seams 22), and the overlapping edges 25 of the skin pieces 21 (i.e., the seam allowances) protrude inside the bag-shaped skin material 20 (see FIGS. 2 and 6B).

[0010] FIG. 3 shows the bag-shaped skin material 20 in a turned-over state. The overlapped edges 25 of the skin pieces 21 include a pair of projecting pieces 27 that form the raw material injection part 20K which communicates the inside and outside of the bag-shaped skin material 20 without being sewn to each other. For example, one raw material injection part 20K is provided, and in the example of the present embodiment, it is arranged on the bottom surface of the bag-shaped skin material 20 (i.e., the headrest) (see FIG. 2). In the example of the present embodiment, the boundary between the skin pieces 21 (the first bottom skin piece 21A and the second bottom skin piece 21B) that form the raw material injection part 20K therebetween extends in the left-right direction, and the pair of projecting pieces 27 face each other in the front-rear direction (see FIG. 2).

[0011] Note that, as will be described later, when the bag-shaped skin material 20 is manufactured by sewing the skin pieces 21, it is manufactured in a turned-over state, and then, with the opening of the raw material injection part 20K as a turning opening, it is turned right side out.

[0012] As shown in FIG. 3, the raw material injection part 20K is provided in the middle of the width direction (left-right direction) of the pair of projecting pieces 27. The raw material injection part 20K is provided in the portion of the pair of projecting pieces 27 that are not sewn to each other as described above, and this portion opens so that the pair of projecting pieces 27 move away from each other, thereby opening the raw material injection part 20K. In the foamed molded product 10 with skin of the present embodiment, the raw material injection part 20K is closed by the foamed molded body 15 pressing the pair of projecting pieces 27 against each other (see FIG. 2).

[0013] As shown in FIG. 2, in the example of the present embodiment, the foamed molded product 10 with skin has a substantially triangular shape in side view, and as three corner parts, it has an upper corner part 29A that forms the top, a front corner part 29B that forms the front end of the bottom surface, and a rear corner part 29C that forms the rear end of the bottom surface. The foamed molded product 10 with skin (bag-shaped skin material 20) has a bottom surface on which the raw material injection part 20K is arranged between the front corner part 29B and the rear corner part 29C, and the front corner part 29B is closer to the upper corner part 29A (i.e., above) than the rear corner part 29C. Therefore, the bottom surface of the foamed molded product with skin (bag-shaped skin material 20) is inclined downward to the rear.

[0014] As shown in FIGS. 2 and 3, in the example of the present embodiment, as the plurality of skin pieces 21 constituting the bag-shaped skin material 20, the above-described first bottom skin piece 21A and second bottom skin piece 21B, a front skin piece 21C, a rear skin piece 21D, and a pair of side skin pieces 21E are provided. The first bottom skin piece 21A and the second bottom skin piece 21B are arranged on the rear side and the front side of the raw material injection portion 20, respectively, at the bottom of the bag-shaped skin material 20. The front skin piece 21C and the rear skin piece 21D constitute the front and rear surfaces of the bag-shaped skin material 20, respectively. The pair of side skin pieces 21E constitute the left and right side surfaces of the bag-shaped skin material 20. In the bag-shaped skin material 20 of the present embodiment, the bottom skin piece 21T composed of the first bottom skin piece 21A and the second bottom skin piece 21B closes the opening of the hood skin piece 21Y composed of the front skin piece 21C, the rear skin piece 21D, and the pair of side skin pieces 21E, and the outer peripheral edge of the bottom skin piece 21T is sewn to the edge of the opening. Further, the sewing portion of the front skin piece 21C and the rear skin piece 21D is arranged at the upper corner portion 29A. The sewing portion of the front skin piece 21C and the bottom skin piece 21T is arranged at the front corner portion 29B. The sewing portion of the rear skin piece 21D and the bottom skin piece 21T is arranged at the rear corner portion 29C.

[0015] As shown in FIGS. 3 and 4A, in the bag-shaped skin material 20 of the present embodiment, a tab sewing portion 37 is formed in which the end portions in the width direction of the pair of tabs 27 are sewn to each other. The tab sewing portion 37 is provided at both end portions in the width direction of the pair of tabs 27, and the above-described raw material injection portion 20 is arranged between these tab sewing portions 37. In the example of the present embodiment, as shown in FIG. 6A, the tab sewing portion 37 is provided with a first sewing portion 31 and a second sewing portion 32 that form an L-shaped sewing line. The first sewing portion 31 extends in the width direction from both end edges to a position in the middle of the width direction (for example, a position near both end edges) of the pair of tabs 27. The second sewing portion 32 extends from the inner ends in the width direction of the pair of tabs 27 in the first sewing portion 31 to the tip ends of the pair of tabs 27. And the raw material injection portion 20 is provided between the pair of second sewing portions 32.

[0016] As shown in FIGS. 3 and 4A, in the bag-shaped skin material 20 of the present embodiment, edge sewing portions 30 are formed at the widthwise ends of the pair of projecting pieces 27 in a fallen state and sewn to the skin piece 21 (in the example of the present embodiment, the bottom skin piece 21T). In the example of the present embodiment, the widthwise ends of the pair of projecting pieces 27 fall to opposite sides in a crotch-opening state (folded back at the first sewing portion 31), overlap the edge of the bottom skin piece 21T, and are sewn to the bottom skin piece 21T together with the side skin piece 21E (see FIGS. 4B and 5).

[0017] As shown in FIGS. 6A and 6B, a cut portion 35 formed by cutting the first projecting piece 27A of one of the pair of projecting pieces 27 (the first bottom skin piece 21A) from the tip is formed in the first projecting piece 27A. The cut portion 35 is formed between the raw material injection portion 20K and the edge sewing portion 30 in the width direction of the first projecting piece 27A. In the example of the present embodiment, the cut portion 35 is a cut extending from the tip of the first projecting piece 27A toward the base end side. Note that in the example of the present embodiment, the cut portion 35 is not formed in the second projecting piece 27B of the other of the pair of projecting pieces 27 (the second bottom skin piece 21B). Here, when the bag-shaped skin material 20 is arranged in a posture in which the upper corner portion 29A is located at the central portion in the front-rear direction (hereinafter, appropriately referred to as the "reference posture") (see FIGS. 2 and 8), in a configuration where the distance between the upper corner portion 29A and the front corner portion 29B and the distance between the upper corner portion 29A and the rear corner portion 29C are different, the bottom surface of the bag-shaped skin material 20 is inclined with respect to the vertical direction. The first projecting piece 27A in which the cut portion 35 of the present embodiment is formed is formed of the first bottom skin piece 21A disposed on the side (the lower side in FIG. 2 and the upper side in FIG. 8) away from the upper corner portion 29A on the inclined bottom surface of the bag-shaped skin material 20.

[0018] As described above, in the example of this embodiment, by forming the cut portion 35, the first protruding piece 27A is divided in the width direction between the raw material injection portion 20K and the edge sewing portion 30. As a result, it is possible to suppress the raw material injection portion 20K from falling to one side (the side of the first protruding piece 27A provided with the cut portion 35), and allow it to fall to the other side (the side of the second protruding piece portion not provided with the cut portion). Therefore, when molding the foamed molded body 15, it is possible to easily maintain the raw material injection portions 20K of the pair of protruding pieces in a state of standing upright with respect to the bottom surface of the bag-shaped skin material 20 (at the central portion in the width direction in the example of this embodiment). Moreover, since the cut portion 35 is formed only on the first protruding piece 27 among the pair of protruding pieces 27, when injecting the raw material G of the foamed molded body 15, the raw material injection portions 20K of the pair of protruding pieces can be set in a state of being slightly tilted toward the second bottom skin piece 21B side (the front corner portion 29B side) with respect to the bottom surface of the bag-shaped skin material 20 (see FIG. 7).

[0019] The foamed molded product 10 with skin of this embodiment is manufactured, for example, as follows. First, a bag-shaped skin material 20 is prepared. As shown in FIGS. 6A and 6B, the edges 25 of the first bottom skin piece 21A and the second bottom skin piece 21B are sewn together (a protruding piece sewing portion 37 is formed), a bottom skin piece 21T is formed, and a pair of protruding pieces 27 having a raw material injection portion 20K is formed. Then, the outer edge portion of this bottom skin piece 21T is sewn to the opening edge portion of the hood skin piece 21Y (see FIG. 3). For example, at this time, the end portions in the width direction of the pair of protruding pieces 27 are tilted to opposite sides in a crotch-opening state, and by this sewing, they overlap the edge of the bottom skin piece 21T and are sewn to the bottom skin piece 21T together with the side skin piece 21E (see FIGS. 3 and 4A). Thereby, an inside-out bag-shaped skin material 20 is formed. Here, a cut portion 35 (a notch) is formed between the raw material injection portion 20K and the edge sewing portion 30 in the first protruding piece 27A disposed below the second protruding piece 27B on the inclined bottom surface of the bag-shaped skin material 20 in the reference posture shown in FIG. 2. For example, the formation of the cut portion 35 may be performed before or after the sewing of the first bottom skin piece 21A and the second bottom skin piece 21B.

[0020] Next, the bag-shaped skin material 20 in the turned-over state is turned right side out with the opening of the raw material injection part 20 as the turning opening and set in the mold 70. At this time, the bag-shaped skin material 20 is arranged in a reference posture with the upper corner part 29A facing downward so that the upper corner part 29A is at the lowest position (see Fig. 7). Therefore, in the bag-shaped skin material 20 set in the mold 70, its bottom surface is in an inclined state with the front corner part 29B on the lower side and the rear corner part 29C on the upper side. Then, the raw material G of the foam molded body 15 is injected into the inside of the bag-shaped skin material 20 from the raw material injection part 20 (see Fig. 7). At this time, since the pair of protruding pieces 27 (raw material injection part 20K) can be in a state slightly tilted toward the front corner part 29B with respect to the bottom surface of the bag-shaped skin material 20 (for example, a state extending in the vertical direction), it becomes possible to inject the raw material G toward the upper corner part 29A where the injection nozzle N is at the lowest position, and the foaming in the bag-shaped skin material 20 becomes stable. For example, if the raw material injection part 20K is arranged at the center in the front-rear direction of the bottom surface of the bag-shaped skin material 20, it becomes possible to arrange the raw material injection part 20K directly above the upper corner part 29A in the reference posture shown in Fig. 7, and it becomes possible to facilitate the injection of the raw material G toward the upper corner part 29A. Note that, as the foam molded body 15, for example, one made of polyurethane foam can be mentioned.

[0021] Next, the mold 70 is closed, and foam molding is performed inside the bag-shaped skin material 20. Then, the foam molded body 15 is integrally molded with the bag-shaped skin material 20, and the foam molded product 10 with skin is formed (see Fig. 9).

[0022] Here, when the raw material G foams and rises inside the bag-shaped skin material 20, as the route for the foamed resin to reach the pair of protruding pieces 27, there are a route X (front route) in which the foamed resin travels along the front skin piece 21C and a route Y (rear route) in which the foamed resin travels along the rear skin piece 21D. In the example of the present embodiment, since the route X is shorter than the route Y, the foamed resin from the route X reaches the pair of protruding pieces 27 (second protruding piece 27B) first. At this time, if the pair of protruding pieces 27 fall backward (toward the rear skin material 21D side) with respect to the bottom surface, when the raw material injection part 20K is closed by the foamed resin, a situation may occur in which the alignment line of the pair of protruding pieces 27 meanders.

[0023] In contrast, as described above, in the example of this embodiment, by forming the cut portion 35 in the first protruding piece 27A, the raw material injection portion 20K of the pair of protruding pieces 27 can inject the raw material G in a state where it is tilted forward (toward the front skin piece 21C side) with respect to the bottom surface, and the foamed resin following the front route (route X) can be made to stand at an angle close to perpendicular to the bottom surface, making it difficult for it to fall backward any further. Therefore, it is possible to prevent the alignment line of the pair of protruding pieces 27 from meandering when the raw material injection portion 20K is closed by the foamed resin. And when the pair of protruding pieces 27 are pressed by the foamed resin from the front and back, it becomes possible to maintain the state where the raw material injection portion 20 is closed, and it is also possible to suppress the resin from leaking from the raw material injection portion 20K.

[0024] [Second Embodiment] FIG. 10 shows the foamed molded article 10 with skin and the bag-shaped skin material 20 of the second embodiment. In the example of this embodiment, the foamed molded article 10 with skin (bag-shaped skin material 20) has a substantially isosceles triangular shape in side view. Also, the raw material injection portions 20 of the pair of protruding pieces 27 are arranged at the center in the front-rear direction of the bottom skin piece 21T. And in the reference posture where the upper corner portion 29A is arranged at the center in the front-rear direction of the bag-side skin material 20, the bottom surface of the bag-shaped skin material 20 is arranged substantially horizontally.

[0025] Also in the example of this embodiment, the ends of the pair of protruding pieces 27 are tilted to opposite sides in a crotch-opening state, overlapped on the edge of the bottom skin piece 21T, and sewn to the bottom skin piece 21T together with the side skin piece 21E to form the edge sewing portion 30 (see FIGS. 11 and 12). However, the point that no cut portion 35 is formed in any of the pair of protruding pieces 27 is different from the above-described first embodiment (see FIG. 13). Even with this configuration, it is possible to make the pair of protruding pieces 27 (raw material injection portion 20K) stand at an angle close to perpendicular to the bottom surface of the bag-shaped skin material 20 (see FIG. 15).

[0026] In the manufacturing method of this embodiment as well, similar to the first embodiment, the bag-shaped skin material 20 is set in the mold 70, and the raw material G is injected into the bag-shaped skin material 20 from the raw material injection part 20 (see FIGS. 14 and 15). Here, as shown in FIG. 15, also in this embodiment, as the route for the foamed resin to reach the pair of protruding pieces 27, there are a route X through which the foamed resin travels along the front skin piece 21C and a route Y through which the foamed resin travels along the rear skin piece 21D, and the lengths of route X and route Y are equal. And even if the timing of the foamed resin traveling along route X and the foamed resin traveling along route Y reaching the raw material injection part 20K of the pair of protruding pieces 27 deviates greatly, the raw material injection parts 20K of the pair of protruding pieces 27 can maintain an upright state that is nearly perpendicular to the bottom surface of the bag-shaped skin material 20, so it is possible to prevent the alignment line of the pair of protruding pieces 27 from meandering.

[0027] [Other Embodiments] The foamed molded product 10 with skin is not limited to the headrest of the seat, and for example, it may be the armrest of the seat. Note that the seat may be for a vehicle (for example, for a car) or for a building.

[0028] In the above first embodiment, the cut part 35 was a notch, but the cut part 35 may be a slit with a width or a notch part in which the protruding piece 27 is notched from the tip.

[0029] In the above first embodiment, the cut part 35 may be formed only on the second protruding piece 27B of the pair of protruding pieces 27. In this case, it is preferable that the bottom surface of the bag-shaped skin material 20 is in an inclined state in which the front corner part 20B is arranged on the side away from the upper corner part 29A more than the rear corner part 29C in the reference posture (in FIG. 2, the front corner part 29B is lower than the rear corner part 29C).

[0030] In the above second embodiment, the cut part 35 may be formed only on one of the pair of protruding pieces 27. For example, the skin piece 21 on the side of the protruding piece 27 where the cut part 35 is formed among the front skin piece 21C and the rear skin piece 21D may be made of a material through which the foamed resin hardly travels along the inner surface.

[0031] In the above-described first embodiment, as shown in FIG. 17, the ends of a pair of projecting pieces 27 may be overlapped with the edge of the bottom skin piece 21T in a state where they are stacked in two layers and fallen to the same side, and sewn to the bottom skin piece 21T together with the side skin piece 21E.

[0032] <Addendum> Hereinafter, the feature groups extracted from the above embodiments will be described while showing effects and the like as necessary. In the following, for ease of understanding, the corresponding configurations in the above embodiments are appropriately shown in parentheses or the like, but these feature groups are not limited to the specific configurations shown in such parentheses or the like.

[0033] For example, the following feature groups of the present disclosure relate to "bag-shaped skin materials and foamed molded articles with skin", and regarding the background art of "as a conventional bag-shaped skin material, a pair of projecting pieces are formed where the edges of the skin material sewn into a bag shape are overlapped and protrude inward, and an injection part for a foamed resin raw material is provided at a portion where these projecting pieces are not sewn together (see, for example, Japanese Patent Application Laid-Open No. 2015-136458 (FIG. 2, etc.)).", it can be considered that they were conceived with the problem of "disclosing a technique capable of improving the appearance of the injection part in a foamed molded article with skin in which a foamed molded body is formed inside a bag-shaped skin material." Further, conventionally, the development of new technologies related to bag-shaped skin materials and foamed molded articles with skin has been demanded.

[0034] [Feature 1] A bag-shaped skin material in which a pair of projecting pieces are formed by overlapping the edges of a part of the skin pieces sewn into a bag shape and protruding inside the bag shape, and a foamed resin raw material injection part (raw material injection part 20K) that is not sewn together is provided in the middle of the pair of projecting pieces in the width direction, The end portions of the pair of projecting pieces in the width direction are edge sewing portions sewn to the skin piece in a fallen state, and A bag-shaped skin material including a cut portion formed between the foamed resin raw material injection part and the edge sewing portion in the width direction of one of the projecting pieces and obtained by cutting the projecting piece from the tip.

[0035] [Feature 2] The bag-shaped skin material according to Feature 1, wherein the cut portion is a notch extending from the tip of the one protruding piece toward the base end side.

[0036] [Feature 3] The bag-shaped skin material according to Feature 1, wherein the edge sewing portion is formed by sewing the end portions in the width direction of the pair of protruding pieces to the skin piece while falling to opposite sides in a crotch-opening state.

[0037] [Feature 4] A bag-shaped skin material in which edge portions of a part of the skin pieces to be sewn together in a bag shape are overlapped to form a pair of protruding pieces protruding inside the bag shape, and a foamed resin raw material injection portion that is not sewn together is provided in the middle of the pair of protruding pieces in the width direction, The bag-shaped skin material includes an edge sewing portion in which the end portions in the width direction of the pair of protruding pieces are sewn to the skin piece while falling to opposite sides in a crotch-opening state.

[0038] [Feature 5] A foamed molded product with skin, comprising a foamed molded body that is integrally foamed with the bag-shaped skin material inside the bag-shaped skin material according to any one of Features 1 to 4.

[0039] [Feature 6] A foamed molded product with skin according to Feature 5, which is a headrest for a vehicle, and the pair of protruding pieces are arranged on the bottom surface portion of the headrest.

[0040] According to the above features, it is possible to improve the appearance of the foamed resin raw material injection portion.

[0041] In addition, although specific examples of the technology included in the claims are disclosed in this specification and the drawings, the technology described in the claims is not limited to these specific examples, and also includes those obtained by variously modifying and changing the specific examples, and those obtained by extracting a part from the specific examples alone.

Description of Symbols

[0042] 10 Foamed molded product with skin 15 Foamed molded body 20 Bag-shaped skin material 20K Raw material injection part 27 Projection 30 Edge sewing part 35 Cut part

Claims

1. A bag-shaped skin material in which edges of a part of a skin piece sewn into a bag shape are overlapped to form a pair of protruding pieces protruding inside the bag shape, and a foamed resin raw material injection part that is not sewn to each other is provided in the middle of the pair of protruding pieces in the width direction, wherein end portions of the pair of protruding pieces in the width direction are edge sewing parts sewn to the skin piece in a fallen state, and the bag-shaped skin material includes a cut part formed by cutting one of the protruding pieces from the tip between the foamed resin raw material injection part and the edge sewing part in the width direction.

2. The bag-shaped skin material according to claim 1, wherein the cut part is a cut extending from the tip of the one protruding piece toward the base end side.

3. The bag-shaped skin material according to claim 1, wherein the edge sewing part is formed by sewing the end portions of the pair of protruding pieces in the width direction to the skin piece while falling to opposite sides in a crotch-opening state.

4. A bag-shaped skin material in which edges of a part of a skin piece sewn into a bag shape are overlapped to form a pair of protruding pieces protruding inside the bag shape, and a foamed resin raw material injection part that is not sewn to each other is provided in the middle of the pair of protruding pieces in the width direction, wherein the edge sewing part is provided, in which end portions of the pair of protruding pieces in the width direction are sewn to the skin piece while falling to opposite sides in a crotch-opening state.

5. A foamed molded product with skin, comprising a foamed molded body integrally foamed with the bag-shaped skin material inside the bag-shaped skin material according to any one of claims 1 to 4.

6. The foamed molded product with skin according to claim 5, which is a headrest for a vehicle, wherein the pair of protruding pieces are arranged on the bottom surface part of the headrest.

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