JPH11300767A - Method for molding skin-integrated molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for molding a skin-integrated molded product which can mold a skin-integrated molding economically in good work efficiency. SOLUTION: A skin is formed by a process in which in a molding mold 10 having mold surfaces 12, 22 of prescribed shapes in which pressure feed parts 31 are formed on split surfaces 13, 23, films for skin 41, 42 are held between the split surfaces 13, 23 to hold the feed parts 31 vertically, air G is supplied to the insides of the films 41, 42 through the feed parts 31 to expand in the shape of the mold surfaces 12, 22 of the molding mold 10. Next, foaming material beads are introduced into the skin molded in the shape of mold surfaces of the molding mold 10 through the feed parts, and foaming is done to be integrated with the skin.

Description

【発明の詳細な説明】DETAILED DESCRIPTION OF THE INVENTION

【０００１】[0001]

【発明の属する技術分野】この発明は、表皮一体成形品
の成形方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming an integral skin product.

【０００２】[0002]

【従来の技術】近年、浮きやブイ、あるいは枕や丸座等
のクッション等に、発泡体を表皮で覆った表皮一体成形
品が多用されている。前記表皮一体成形品の成形方法と
して、表皮一体発泡成形法がある。その表皮一体発泡成
形法は、所望成形品形状に形成された表皮を成形型の型
面に沿うように配置し、その表皮内側にビーズ状発泡材
料を導入して発泡体を形成し、その際の発泡材料の接着
性により表皮と発泡体を一体にした後、成形品を成形型
から脱型するもので、発泡体の形成と同時に発泡体と表
皮との一体化を行える利点がある（特許第２６７０６６
１号，同第２６８１７３０号等）。2. Description of the Related Art In recent years, a skin integral molded product in which a foam is covered with a skin is frequently used for a float, a buoy, a cushion such as a pillow or a round seat. As a method of molding the above-mentioned integral skin molded article, there is an integral skin foam molding method. In the skin integral foam molding method, a skin formed into a desired molded product shape is arranged along a mold surface of a molding die, a bead-like foam material is introduced into the inside of the skin, and a foam is formed. After the skin and the foam are integrated by the adhesive property of the foam material, the molded product is removed from the mold, and there is an advantage that the foam and the skin can be integrated simultaneously with the formation of the foam (Patent 267066
No. 1 and No. 2681730).

【０００３】しかるに、上記表皮一体発泡成形法におい
ては、発泡体を覆う表皮を、発泡成形に先立って、公知
の真空成形やスラッシュ成形、あるいはブロー成形等に
より別成形しているため、作業効率が悪いといった問題
がある。また、表皮を得るための設備と発泡成形のため
の設備とを別個に用意しなければならず、設備コストが
嵩んでしまうといった問題もある。However, in the above-mentioned skin integral foam molding method, the skin covering the foam is formed separately by a known vacuum molding, slash molding, blow molding or the like prior to the foam molding. There is a problem such as bad. In addition, a facility for obtaining the skin and a facility for foam molding must be separately prepared, and there is a problem that the facility cost increases.

【０００４】[0004]

【発明が解決しようとする課題】そこで、この発明は、
前記の問題点に鑑みなされたもので、表皮一体成形品を
作業効率良く、しかも経済的に成形することができる表
皮一体成形品の成形方法を提供しようとするものであ
る。SUMMARY OF THE INVENTION Therefore, the present invention
In view of the above problems, an object of the present invention is to provide a method for molding a skin integral molded product that can be molded efficiently and economically.

【０００５】[0005]

【課題を解決するための手段】請求項１の発明は、割り
面に圧送部を形成した所定形状の型面を有する成形型
に、前記圧送部を上下に挟むように表皮用フィルムを前
記割り面で挟持し、該表皮用フィルムの内側に前記圧送
部を介して空気を圧送して前記成形型の型面形状に膨張
させ賦形して表皮を形成し、次いで、前記成形型の型面
形状に賦形された表皮の内部に前記圧送部を介してビー
ズ状発泡材料を導入し、該表皮と一体に発泡成形するこ
とを特徴とする表皮一体成形品の成形方法に係る。According to a first aspect of the present invention, a film for skin is divided into a mold having a die surface of a predetermined shape in which a pressing portion is formed on a split surface so as to vertically sandwich the pressing portion. Surface, and pressurize air into the inside of the skin film through the pumping section to expand and shape the mold surface of the mold to form a skin, and then form a mold surface of the mold. The present invention relates to a method for molding a skin-integrated molded product, which comprises introducing a bead-like foamed material into the interior of a shaped skin through the pumping section, and foam-molding the same integrally with the skin.

【０００６】また、請求項２の発明は、請求項１におい
て、前記圧送部が廃棄可能なパイプ状物である表皮一体
成形品の成形方法に係る。[0006] The invention of claim 2 relates to the method of forming an integral skin-molded product according to claim 1, wherein the pressure-feeding section is a disposable pipe-like material.

【０００７】[0007]

【発明の実施の形態】以下添付の図面に従ってこの発明
を詳細に説明する。図１はこの発明に係る成形方法の一
実施例に用いる成形型の一例を示す概略斜視図、図２は
同実施例における表皮用フィルムの挟持時を示す概略斜
視図、図３は図２の３−３切断面を示す断面図、図４は
同実施例における空気の圧送時を示す断面図、図５は同
実施例における表皮用フィルムの賦形完了時を示す断面
図、図６は同実施例における発泡材料導入時を示す断面
図、図７は同実施例における発泡体の形成完了時を示す
断面図、図８は同実施例におけるトリミング時を示す断
面図である。DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the accompanying drawings. FIG. 1 is a schematic perspective view showing an example of a molding die used in an embodiment of a molding method according to the present invention, FIG. 2 is a schematic perspective view showing a state in which a skin film is clamped in the embodiment, and FIG. 3 is a cross-sectional view showing a cut surface, FIG. 4 is a cross-sectional view at the time of air pumping in the same embodiment, FIG. 5 is a cross-sectional view showing the completion of shaping of the skin film in the same embodiment, and FIG. FIG. 7 is a cross-sectional view of the embodiment when the foam material is introduced, FIG. 7 is a cross-sectional view of the embodiment when the formation of the foam is completed, and FIG. 8 is a cross-sectional view of the embodiment when the trimming is performed.

【０００８】まず、この発明に係る表皮一体成形品の成
形方法の一実施例に用いる成形型の一例について、図１
ないし図３に基づいて説明する。図示の成形型１０は、
表皮の形成と表皮一体発泡成形を併せて行うことができ
るもので、下型１１と上型２１とを備える。なお、前記
下型１１と上型２１は適宜手段で開閉できるように構成
されている。First, an example of a molding die used in one embodiment of a method for molding a skin integral molded product according to the present invention will be described with reference to FIG.
A description will be given based on FIG. The illustrated mold 10 includes:
It is capable of performing both skin formation and integral skin foam molding, and includes a lower mold 11 and an upper mold 21. The lower mold 11 and the upper mold 21 are configured to be opened and closed by appropriate means.

【０００９】前記下型１１および上型２１は、所望成形
品表面形状に形成された型面１２，２２をそれぞれ有
し、該型面１２，２２の外周は、割り面（パーティング
面）１３，２３となっている。そして、前記割り面１３
および２３の所定位置には、表皮を形成する際に空気を
圧送し、かつ発泡成形の際に発泡材料を導入するための
圧送部３１が適宜数（この例では一個）形成されてい
る。当該圧送部３１は、表皮形成時には吹き込み装置の
ノズル部Ｂａと接続され、発泡成形時には発泡材料供給
装置のノズル部（Ｅａ）とそれぞれ接続される。そし
て、この例における圧送部３１は、請求項２の発明のよ
うにゴム製チューブ等の廃棄可能なパイプ状物とされて
いる。図示の符号１４，２４は前記割り面１３，２３に
形成された前記圧送部３１のための凹部である。The lower mold 11 and the upper mold 21 have mold surfaces 12 and 22 respectively formed in a desired molded product surface shape, and the outer periphery of the mold surfaces 12 and 22 has a split surface (parting surface) 13. , 23. And the split surface 13
At predetermined positions of and 23, an appropriate number (one in this example) of pressure feeding portions 31 for feeding air when forming the skin and introducing a foam material at the time of foam molding is formed. The pressure feeding section 31 is connected to the nozzle section Ba of the blowing device at the time of forming the skin, and is connected to the nozzle section (Ea) of the foaming material supply apparatus at the time of foam molding. The pumping section 31 in this example is a disposable pipe such as a rubber tube as in the second aspect of the present invention. Reference numerals 14 and 24 shown in the drawings are recesses formed on the split surfaces 13 and 23 for the pressure feeding unit 31.

【００１０】また、この例では、前記下型１１の内部お
よび上型２１の内部には、型面１２および２２を所定温
度に調節するために、スチーム等の温調手段Ｈが設けら
れている。なお、前記下型１１および上型２１は、成形
品形状が複雑な場合等には、割型とされることもある。
さらに、前記圧送部３１の空気圧送による表皮形成をよ
りスムーズに行うため、および発泡成形時に表皮と型面
１２，２２間に隙間が生じ成形不良を起こすのを防止す
るため、当該成形型１０に真空吸引手段を設けてもよ
い。In this embodiment, a temperature control means H such as steam is provided inside the lower mold 11 and the upper mold 21 to adjust the mold surfaces 12 and 22 to a predetermined temperature. . The lower mold 11 and the upper mold 21 may be split molds when the shape of the molded product is complicated.
Furthermore, in order to more smoothly form the skin by air pressure feeding of the pumping unit 31 and to prevent a gap from being formed between the skin and the mold surfaces 12 and 22 at the time of foam molding, and to prevent molding failure, the molding die 10 is used. Vacuum suction means may be provided.

【００１１】次に、前記成形型１０を用いて行う表皮一
体成形品の成形方法の一実施例について説明する。ま
ず、図２および図３に示すように、前記成形型１０の下
型１１と上型２１間に二枚の表皮用フィルム４１，４２
を配置し、該成形型１０を型閉めすることによって、前
記二枚の表皮用フィルム４１，４２を前記成形型１０の
割り面１３，２３で挟持する。この際、前記表皮用フィ
ルム４１，４２が前記圧送部３１を上下に挟むようにす
る。前記表皮用フィルム４１，４２には、ポリエチレン
（ＰＥ），ポリエチレンテレフタレート（ＰＥＴ），塩
化ビニル樹脂（ＰＶＣ），ポリプロピレン（ＰＰ）等か
らなるシート状物が用いられる。なお、この実施例にお
いては、前記各フィルム４１，４２は、単層とされてい
るが、複数層とされる場合もある。Next, an embodiment of a method for forming an integral skin molded product using the molding die 10 will be described. First, as shown in FIGS. 2 and 3, two skin films 41 and 42 are provided between the lower mold 11 and the upper mold 21 of the molding die 10.
Is arranged, and the mold 10 is closed, whereby the two skin films 41 and 42 are sandwiched between the split surfaces 13 and 23 of the mold 10. At this time, the skin films 41 and 42 sandwich the pumping unit 31 up and down. As the skin films 41 and 42, a sheet material made of polyethylene (PE), polyethylene terephthalate (PET), vinyl chloride resin (PVC), polypropylene (PP), or the like is used. In this embodiment, each of the films 41 and 42 has a single layer, but may have a plurality of layers.

【００１２】続いて、図４に示すように、前記表皮用フ
ィルム４１，４２の内側（フィルム４１，４２の合わせ
目）に、前記成形型１０外の吹き込み装置から前記圧送
部３１を介して空気Ｇを圧送して、図５に示すように、
当該表皮用フィルム４１，４２を前記成形型１０の型面
１２，２２形状に膨張させ賦形（中空成形）して、表皮
４３（４１ａ，４２ａ）を形成する。この際、前記型面
１２，２２は、前記温調手段Ｈによって所定温度に加熱
されている。この加熱温度は、用いる表皮用フィルム４
１，４２の材質等を考慮して定める。Subsequently, as shown in FIG. 4, air is blown into the inside of the skin films 41 and 42 (joint portions of the films 41 and 42) from the blowing device outside the molding die 10 through the pressure feeding section 31. G, as shown in FIG.
The skin films 41, 42 are expanded into the shape of the mold surfaces 12, 22 of the molding die 10 and shaped (hollow molding) to form the skins 43 (41a, 42a). At this time, the mold surfaces 12, 22 are heated to a predetermined temperature by the temperature control means H. This heating temperature depends on the skin film 4 to be used.
It is determined in consideration of the materials and the like of 1, 42.

【００１３】なお、前記圧送部３１の空気圧送による表
皮４３（４１ａ，４２ａ）の形成をよりスムーズかつ良
好に行うため、成形型１０に真空吸引手段（図示せず）
を設け、前記成形型１０の型面１２，２２と前記表皮用
フィルム４１，４２間の空気を真空吸引するようにして
もよい。In order to form the outer skin 43 (41a, 42a) more smoothly and favorably by pneumatic feeding of the pumping unit 31, vacuum suction means (not shown) is applied to the molding die 10.
May be provided, and the air between the mold surfaces 12, 22 of the molding die 10 and the skin films 41, 42 may be suctioned by vacuum.

【００１４】次いで、図６に示すように、前記成形型１
０の型面１２，２２形状に賦形された表皮４３の内部
に、前記発泡材料供給装置から前記圧送部３１を介して
ビーズ状発泡材料Ｍを導入する。前記表皮４３内部に導
入されたビーズ状発泡材料Ｍは、前記温調手段Ｈにより
所定温度に加熱された型面１２，２２の熱が前記表皮４
３を介して伝わることによって発泡し、図７に示すよう
に発泡体４５を形成する。そして、この発泡体４５は、
発泡材料Ｍの発泡時に表皮４３と一体化し、表皮４３と
発泡体４５とが一体となった成形品４０を成形型１０内
に形成する。なお、前記型面１２，２２の加熱温度は用
いるビーズ状発泡材料Ｍの材質等を考慮して定められ
る。Next, as shown in FIG.
The bead-shaped foamed material M is introduced from the foamed material supply device via the pumping unit 31 into the inside of the skin 43 shaped into the shape of the mold surfaces 12 and 22 of zero. The bead-shaped foamed material M introduced into the outer skin 43 is heated by the temperature adjusting means H to a predetermined temperature, and the heat of the mold surfaces 12 and 22 is reduced by the outer skin 4.
3 to form a foam 45 as shown in FIG. And this foam 45
When the foam material M is foamed, it is integrated with the skin 43, and the molded product 40 in which the skin 43 and the foam 45 are integrated is formed in the mold 10. The heating temperature of the mold surfaces 12, 22 is determined in consideration of the material of the bead-shaped foam material M to be used.

【００１５】ここで、前記ビーズ状発泡材料Ｍとして
は、例えば、直径が１ｍｍ〜３ｍｍ程度のポリスチレン
やポリオレフィン樹脂等に、予め揮発性発泡剤を含浸さ
せた高発泡可能なものが用いられる。なお、前記発泡材
料Ｍには発泡助剤，コーティング剤，難燃剤等が適宜配
合される。Here, as the bead-shaped foam material M, for example, a highly foamable material obtained by impregnating a volatile foaming agent in advance into polystyrene or polyolefin resin having a diameter of about 1 mm to 3 mm is used. In addition, a foaming aid, a coating agent, a flame retardant, and the like are appropriately compounded in the foam material M.

【００１６】なお、前記発泡時、前記表皮４３内部の発
泡材料Ｍは、前記圧送部３１の先端３２付近あるいは、
圧送部３１内まで発泡するが、請求項２の発明として記
載したように、該圧送部３１をプラスチックまたはゴム
製チューブ等の廃棄可能なパイプ状物によって構成し、
成形後に当該圧送部３１の発泡材料Ｍが詰まった不要部
分を切除すればよい。At the time of the foaming, the foam material M inside the skin 43 may be in the vicinity of the front end 32 of the pressure feeding section 31 or
It foams up to the inside of the pumping section 31, but as described in the invention of claim 2, the pumping section 31 is made of a disposable pipe-like material such as a plastic or rubber tube,
It is only necessary to cut off unnecessary portions of the pumping portion 31 where the foam material M is clogged after the molding.

【００１７】前記発泡体４５の形成後、図８に示すよう
に、前記成形型１０の型開きを行い、成形品４０の脱型
を行うとともに、成形品４０の製品部分４０Ａ外周の不
要部分４０Ｂを切除するトリミングを行うことによっ
て、発泡体が表皮で覆われた所望の製品が得られる。な
お、この実施例では、図示のように、前記不要部分４０
Ｂの切除と同時にあるいはその後、前記圧送部３１の表
皮４３で挟まれた部分３３を切除する。After the foam 45 is formed, as shown in FIG. 8, the mold 10 is opened to remove the molded product 40, and the unnecessary portion 40B of the outer periphery of the product portion 40A of the molded product 40 is removed. The desired product in which the foam is covered with the epidermis can be obtained by performing trimming for cutting off. In this embodiment, as shown in FIG.
Simultaneously with or after the cutting of B, the portion 33 sandwiched between the skins 43 of the pumping section 31 is cut.

【００１８】[0018]

【発明の効果】以上図示し説明したように、この発明の
表皮一体成形品の成形方法によれば、一の成形型により
表皮の形成と発泡成形を同時に行うため、作業効率良
く、しかも設備コストを抑え、経済的に表皮一体成形品
を成形することができる。また、この発明においては、
表皮の形成時における空気の圧送と発泡成形時における
発泡材料の導入を一の圧送部により行うので、成形型の
構造が複雑にならず、この種成形において極めて有利で
ある。As shown and described above, according to the method for molding a skin-integrated molded product of the present invention, the formation of the skin and the foam molding are performed simultaneously by one molding die, so that the work efficiency is high and the equipment cost is high. , And it is possible to economically form the integral skin molded article. In the present invention,
Since the air supply during the formation of the skin and the introduction of the foaming material during the foam molding are performed by a single pumping section, the structure of the mold does not become complicated, which is extremely advantageous in this type of molding.

【００１９】また、請求項２の発明のように、前記圧送
部を廃棄可能なパイプ状物とすれば、発泡成形時に発泡
材料が前記圧送部内まで発泡した場合でも、成形後、当
該圧送部の発泡材料が詰まった不要部分を切除し廃棄す
ることができるので、当該圧送部内に詰まった発泡材料
を取り除く必要はなくなり、この発明に係る成形を繰り
返し作業効率良く行うことができる。Further, if the pumping section is made of a discardable pipe as in the second aspect of the present invention, even if the foamed material foams up to the inside of the pumping section during foam molding, after the molding, the pumping section may be disposed. Since the unnecessary portion clogged with the foam material can be cut off and discarded, there is no need to remove the foam material clogged in the pumping portion, and the molding according to the present invention can be repeatedly performed with high work efficiency.

【図面の簡単な説明】[Brief description of the drawings]

【図１】この発明に係る成形方法の一実施例に用いる成
形型の一例を示す概略斜視図である。FIG. 1 is a schematic perspective view showing an example of a molding die used in an embodiment of a molding method according to the present invention.

【図２】同実施例における表皮用フィルムの挟持時を示
す概略斜視図である。FIG. 2 is a schematic perspective view showing a state in which the skin film is sandwiched in the embodiment.

【図３】図２の３−３切断面を示す断面図である。FIG. 3 is a sectional view showing a section taken along line 3-3 in FIG. 2;

【図４】同実施例における空気の圧送時を示す断面図で
ある。FIG. 4 is a cross-sectional view showing the air pressure feeding in the embodiment.

【図５】同実施例における表皮用フィルムの賦形完了時
を示す断面図である。FIG. 5 is a cross-sectional view showing a time when the shaping of the skin film in the example is completed.

【図６】同実施例における発泡材料導入時を示す断面図
である。FIG. 6 is a cross-sectional view showing the same example when a foam material is introduced.

【図７】同実施例における発泡体の形成完了時を示す断
面図である。FIG. 7 is a cross-sectional view showing a state at the time when the formation of the foam in the example is completed.

【図８】同実施例におけるトリミング時を示す断面図で
ある。FIG. 8 is a cross-sectional view showing trimming in the embodiment.

【符号の説明】[Explanation of symbols]

１０ 成形型 １２，２２ 型面 １３，２３ 割り面 ３１ 圧送部 ４０ 表皮一体成形品 ４１，４２ 表皮用フィルム ４３ 表皮 Ｇ 圧送用空気 Ｍ ビーズ状発泡材料 REFERENCE SIGNS LIST 10 Mold 12, 22 Mold surface 13, 23 Split surface 31 Pressurized part 40 Integrated skin product 41, 42 Skin film 43 Skin G Pressurized air M Bead foam material

Claims (2)

【特許請求の範囲】[Claims] 【請求項１】 割り面に圧送部を形成した所定形状の型
面を有する成形型に、前記圧送部を上下に挟むように表
皮用フィルムを前記割り面で挟持し、該表皮用フィルム
の内側に前記圧送部を介して空気を圧送して前記成形型
の型面形状に膨張させ賦形して表皮を形成し、次いで、
前記成形型の型面形状に賦形された表皮の内部に前記圧
送部を介してビーズ状発泡材料を導入し、該表皮と一体
に発泡成形することを特徴とする表皮一体成形品の成形
方法。1. A skin film is sandwiched between said split surfaces so as to sandwich said pump portion up and down in a molding die having a mold surface of a predetermined shape in which a split portion is formed with a pressing portion. To form a skin by inflating and shaping the air into the mold surface shape of the mold by pumping air through the pumping section,
A method of molding a skin-integrated molded product, comprising introducing a bead-like foam material into the interior of a skin formed into a mold surface shape of the molding die through the pumping portion, and foam-molding the skin integrally with the skin. . 【請求項２】 請求項１において、前記圧送部が廃棄可
能なパイプ状物である表皮一体成形品の成形方法。2. The method according to claim 1, wherein the pressure-feeding section is a disposable pipe-like article.