WO2009145089A1 - 金型及び樹脂発泡成形品の成形方法 - Google Patents
金型及び樹脂発泡成形品の成形方法 Download PDFInfo
- Publication number
- WO2009145089A1 WO2009145089A1 PCT/JP2009/059263 JP2009059263W WO2009145089A1 WO 2009145089 A1 WO2009145089 A1 WO 2009145089A1 JP 2009059263 W JP2009059263 W JP 2009059263W WO 2009145089 A1 WO2009145089 A1 WO 2009145089A1
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- WIPO (PCT)
- Prior art keywords
- mold
- cavity
- vent hole
- resin
- molding
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/10—Moulds or cores; Details thereof or accessories therefor with incorporated venting means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
- B29C37/006—Degassing moulding material or draining off gas during moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/58—Moulds
- B29C44/587—Moulds with a membrane, e.g. for pressure control
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/58—Moulds
- B29C44/588—Moulds with means for venting, e.g. releasing foaming gas
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S425/00—Plastic article or earthenware shaping or treating: apparatus
- Y10S425/812—Venting
Definitions
- the present invention relates to a mold for molding a resin foam molded product such as a vehicle seat cushion, and a method for molding a resin foam molded product using the mold.
- foamed molded products such as flexible polyurethane foam have been used for interior parts such as seats and doors for vehicles such as cars and trains.
- a predetermined amount of a foamed resin raw material for forming a flexible polyurethane foam is supplied into the molding die.
- the molding die is clamped to foam and cure the foamed resin material.
- the expanded resin raw material is molded into a shape corresponding to the cavity while gradually filling the cavity while expanding.
- the molded product may have defects such as lacking or voids.
- vent the gas in the mold by providing a vent hole in the molding die.
- the vent hole is simply provided, the foamed resin material filled in the cavity may be discharged from the vent hole to the outside of the mold, resulting in material loss and the need to clean the vent hole. was there.
- a non-breathable sheet 32 capable of covering the vent hole 31 is attached as a mold 30 configured to prevent the raw material from being discharged from the vent hole as shown in FIGS.
- the air-permeable plate-like slab or the non-woven fabric 33 arranged in the molding die 30 is described.
- gas passes through the slab or the nonwoven fabric 33 and flows out from the vent hole 31 in the foaming process.
- the non-breathable sheet 32 is pressed against the vent hole 31 by the foaming pressure of the foamed resin material to close it. As a result, the resin 35 is prevented from entering the vent hole 31.
- the vent hole 31 is directly open to the atmosphere, so that the gas flowing from the cavity 34 through the vent hole 31 to the outside of the mold The flow rate is large. Therefore, the foamed resin 35 in the cavity 34 proceeds in the cavity 34 toward the vent hole 31, and the non-breathable sheet 32 blocks the vent hole 31 before the cavity 34 is filled with the resin 35. As a result, there is a possibility that gas discharge from the cavity 34 may be insufficient.
- the vent hole 31 is provided in the ceiling portion of the mold 30, so that the slab or the non-woven fabric 33 facing the vent hole 31 is attached to the cavity ceiling.
- the pin 36 for attaching to a surface is required, and the structure of the metal mold
- the present invention solves the above-described conventional problems, can sufficiently discharge gas from the cavity, and can be configured to prevent the resin from entering the vent hole, and the mold
- An object of the present invention is to provide a method for molding a resin foam-molded product using the above.
- the mold according to the first aspect is a mold having a cavity surrounded by at least an upper mold and a lower mold.
- the cavity includes a cavity main part to which a foamed resin raw material is supplied, and foaming at the cavity main part.
- a vent hole is provided in a vertical surface of the cavity end portion.
- the mold according to the second aspect is characterized in that, in the first aspect, an attachment member having a vent hole communicating with the vent hole is detachably attached.
- the mold according to the third aspect is characterized in that, in the second aspect, at least a part of the vent hole has a passage sectional area smaller than that of the vent hole.
- the mold according to the fourth aspect is characterized in that, in any one of the first to third aspects, a cavity side of the vent hole is covered with a ventilation material.
- the mold according to the fifth aspect is characterized in that, in the fourth aspect, the ventilation material is made of a nonwoven fabric, a slab, a press felt, or a urethane compression chip material.
- a mold according to a sixth aspect is the fourth or fifth aspect, wherein the mold includes a core mold, the vent hole is provided in the core mold, and the ventilation material is attached to the core mold. It is characterized by being.
- a mold according to a seventh aspect is any one of the first to sixth aspects, wherein the mold is for molding a vehicle seat pad, and the cavity end portion is disposed above the cavity main portion.
- the cavity main part and the cavity end part communicate with each other via a cavity side part, and the vent hole is provided on a vertical surface opposite to the cavity side part. .
- the mold according to an eighth aspect is characterized in that, in the seventh aspect, the vent hole is provided on a vertical surface most distant from the side of the cavity.
- the molding method for the resin foam molded product of the ninth aspect uses the mold described in any one of the first to eighth aspects.
- a vent hole is provided in the vertical surface of the main cavity portion of the mold.
- the resin foamed in the cavity finally reaches the cavity end.
- the gas generated in the foam molding process and the air in the cavity are formed by the resin and the cavity wall surface.
- there is a vent hole in the cavity end portion as in the above configuration the residual gas flows out from the vent hole, so that resin filling defects are suppressed.
- an attachment member having a vent hole communicating with the vent hole is detachably attached. Therefore, the flow resistance of the gas flowing out from the vent hole through the vent hole of the attachment member is large, and the gas does not flow out of the vent hole vigorously. Therefore, the resin foamed in the cavity receives a counter pressure from the gas remaining in the cavity end portion and gradually expands so as to fill the cavity sequentially.
- the entire inside of the cavity is sufficiently filled with the resin, and a molded product having no lack can be formed.
- the outflow speed of the gas from the cavity can be suppressed by making the passage cross-sectional area of at least a part of the vent hole of the attachment member connected to the vent hole smaller than the vent hole.
- a nonwoven fabric, a slab, a press felt or a urethane compression chip material is suitable.
- a product in which felt or the like is integrated with urethane may be used.
- foaming is performed by attaching a ventilation material such as felt in advance to the core mold, it is preferable to cover the cavity side of the vent hole with this ventilation material.
- the vent hole is provided in the vertical surface of the upper mold cavity surface, the vent hole can be covered with the ventilation material by extending a part of the ventilation material attached to the core mold. . Therefore, a pin for attaching the ventilation material to the cavity surface is unnecessary, and the structure of the mold is simplified.
- the mold of the present invention is suitable for molding vehicle seat pads and the like.
- a cavity end portion is disposed above the cavity main portion, and the cavity main portion and the cavity end portion communicate with each other via the cavity side portion. Some are provided on the vertical surface opposite the side.
- the resin rises from the cavity main part through the cavity side part and foams so as to fill the cavity end part. Therefore, by placing a vent hole on the vertical surface of the cavity end portion opposite to the cavity side portion, particularly the vertical surface that is farthest from the cavity side portion, the entire cavity end portion can be filled with resin. it can.
- FIG. 1 is a longitudinal sectional view of a mold according to an embodiment
- FIG. 2 is a sectional view of this mold during foam molding
- FIG. 3 is a molded vehicle seat pad (back pad).
- the mold 1 has a lower mold 2, an upper mold 4, and a core mold 3 attached to the upper mold 4.
- the lower mold 2 and the upper mold 4 are matched with each other at their peripheral portions.
- the cavity of the mold 1 is connected to the cavity main part 5a below the core mold 3, the cavity side part 5b connected to one end side of the cavity main part 5a, and the cavity side part 5b. And a cavity end portion 5c located on the upper side.
- the cavity has a cavity side portion 5d that is continuous with the other end side of the cavity main portion 5a, and a cavity end portion 5e that is continuous with the cavity side portion 5d and is located above the core mold 3.
- a protrusion 2a for forming the skin hanging groove 21 in the back pad 20 is provided on the cavity surface of the lower mold 2 facing the cavity main portion 5a.
- the core mold 3 is provided with a protrusion 3a for forming the headrest insertion hole 22 in the back pad 20 so as to protrude from the cavity side portion 5b. Further, the core mold 3 is provided with wall portions 3b and 3c that constitute the innermost vertical surface of the cavity end portions 5c and 5e. The upper ends of the walls 3b and 3c are matched with the upper mold 4.
- a vent hole 6 is provided in each of the wall portions 3b and 3c.
- the attachment member 7 is detachably attached to the outer surface side of the walls 3b and 3c.
- the attachment member 7 has a cylindrical shape having a pore-shaped air hole communicating with the vent hole 6, and one end side in the cylinder axis direction is connected to the wall portion 3 b or 3 c. At least a part of the vent holes of the attachment member 7 has a passage sectional area smaller than that of the vent hole 6.
- the base end side of the flexible hose 8 made of rubber, resin or the like is connected to the other end side of the attachment member 7.
- a short tubular end member 9 is connected to the distal end side of the hose 8.
- the vent hole 6 communicates with the atmosphere through the attachment member 7, the hose 8 and the end member 9.
- a ventilation material (nonwoven fabric in this embodiment) 10 such as a nonwoven fabric, a slab, a press felt, or a urethane compression chip material is attached to the core mold 3 so as to cover the surfaces of the core mold 3 facing the cavities.
- the end portion side of the nonwoven fabric 10 also covers the wall portions 3b and 3c, and covers the vent hole 6 from the cavity side.
- the nonwoven fabric 10 is held in the core mold 3 by magnetic force in this embodiment.
- a magnet is provided in the core mold 3, and an iron piece (for example, a wire) is fastened to the nonwoven fabric 10 with an adhesive tape or the like.
- the non-woven fabric 10 is held in the core mold 3 by adsorbing the iron piece to the magnet.
- the iron piece and the adhesive tape are removed after removing the molded product.
- a magnetic tape having magnetic powder such as ferrite powder may be attached to the nonwoven fabric 10.
- the nonwoven fabric 10 is attached to the core mold 3.
- the urethane stock solution When the mold is opened, the urethane stock solution is supplied into the cavity main portion 5a of the lower die 2, and after clamping as shown in FIG. 1, the urethane stock solution is heated to foam. After filling the cavity main portion 5a, the urethane U rises while filling the cavity side portions 5b and 5d, and enters the cavity end portions 5c and 5e.
- this urethane foam Since this urethane foam has viscosity, it forms a lump from the cavity side portions 5b and 5d as shown in FIG. 2 and proceeds toward the walls 3b and 3c. Therefore, the gas and air in the cavity end portions 5 c and 5 e are also discharged through the vent hole 6. In this way, the cavity end portions 5c and 5e are also filled with the urethane foam. Thereafter, after the urethane foam is cured (cured), the mold is opened and demolded.
- the back pad 20 shown in FIG. 3 is obtained.
- the nonwoven fabric 10 is integrally attached to the back surface of the back pad 20.
- a skin hanging groove 21 is provided on the front surface of the back pad 20, and a headrest insertion hole 22 is provided on the upper end surface.
- the lower part 23 of the front surface of the back pad 20 is a part where the occupant's waist hits, the middle part 24 is a part where the rear part hits, and the upper part 25 is a part where the shoulder hits.
- the attachment member 7 having a vent hole communicating with the vent hole 6 is attached to the outer surfaces of the walls 3b and 3c. Therefore, the flow resistance of the gas flowing out from the vent hole 6 through the vent hole of the attachment member 7 is large, and the gas does not flow out of the vent hole 6 vigorously. Therefore, the resin foamed in the cavity receives a counter pressure from the gas remaining in the cavity end portions 5c and 5e, and the cavity main portion 5a, the cavity side portions 5b and 5d, and the cavity end portions 5c and 5e are received in the cavity. It expands gradually so as to fill in sequentially. As a result, the entire inside of the cavity is sufficiently filled with urethane, and a back pad molded product without a lack of thickness can be formed.
- the passage cross-sectional area of at least a part of the vent hole of the attachment member 7 connected to the vent hole 6 is made smaller than the passage cross-sectional area of the vent hole 6, the gas outflow rate from the cavity can be suppressed. it can.
- This vent hole 6 is covered with a nonwoven fabric 10. Since the outflow rate of the gas from the vent hole 6 is small, it is possible to prevent urethane from penetrating through the nonwoven fabric 10 near the vent hole 6 and entering the vent hole 6.
- the nonwoven fabric 10 is held in the core mold 3, and the end side of the nonwoven fabric 10 is raised along the walls 3 b and 3 c so as to cover the cavity 6.
- a pin for attaching to the cavity surface is unnecessary, and the mold structure is simple.
- urethane starts to foam, rises from the cavity main part 5 a through the cavity side parts 5 b and 5 d, and foams so as to fill the cavity end parts 5 c and 5 e.
- the vent holes 6 are arranged on the vertical surfaces of the wall portions 3b and 3c farthest from the cavity side portions 5b and 5d, the cavity ends are not left in the cavity end portions 5c and 5e.
- the whole of the parts 5c and 5e can be filled with urethane. For this reason, it is possible to mold the back pad 20 having no defects such as lack of thickness.
- the non-woven fabric 10 becomes the back side of the back pad 20 and is hidden by the backboard or the like, so that the design of the seat back is not affected.
- the expansion ratio is about 30 to 60 times
- the generated gas amount is about 2 to 10 times the cavity volume
- the cavity volume is about 10 to 25 L
- the diameter of the attachment member 7 is about 8 to 20 mm
- the attachment member 7 The minimum diameter of the air hole is preferably about 0.01 to 0.5 mm, but the present invention is not limited to this.
- the back pad is molded.
- various resin foam molded products can be molded. Resins other than urethane can also be used.
- a vent hole may be provided in the core type vertical direction portion 3d (FIG. 2) facing the cavity side portion 5d, and the attachment member 7 may be connected to the vent hole.
- the diameter of the hole of the end member 9 may be reduced to reduce the gas outflow amount from the cavity.
Abstract
Description
上記実施の形態ではバックパッドを成形しているが、本発明の金型によれば、バックパッドに限らず、各種の樹脂発泡成形体を成形することができる。樹脂としてもウレタン以外のものを用いることができる。
なお、本出願は、2008年5月30日付で出願された日本特許出願(特願2008-143027)に基づいており、その全体が引用により援用される。
Claims (9)
- 少なくとも上型及び下型に囲まれたキャビティを有する金型であって、
該キャビティは、発泡樹脂原料が供給されるキャビティメイン部と、該キャビティメイン部で発泡を開始して膨張してきた樹脂が充填されるキャビティエンド部とを有する樹脂発泡成形用の金型において、
該キャビティエンド部の縦面にベントホールが設けられていることを特徴とする金型。 - 請求項1において、該ベントホールに連通する通気孔を有した付設部材が着脱可能に取り付けられていることを特徴とする金型。
- 請求項2において、該通気孔の少なくとも一部が前記ベントホールよりも通路断面積が小さくなっていることを特徴とする金型。
- 請求項1において、前記ベントホールのキャビティ側が通気素材で覆われていることを特徴とする金型。
- 請求項4において、該通気素材が不織布、スラブ、プレスフェルト又はウレタン圧縮チップ材よりなることを特徴とする金型。
- 請求項4又は5において、金型は中子型を備えており、前記ベントホールは該中子型に設けられており、
該中子型に前記通気素材が装着されていることを特徴とする金型。 - 請求項1において、該金型は車両用シートパッドを成形するためのものであり、
前記キャビティメイン部の上方に前記キャビティエンド部が配置され、該キャビティメイン部とキャビティエンド部とがキャビティ側部を介して連通しており、
前記ベントホールは、該キャビティ側部と反対側の縦面に設けられていることを特徴とする金型。 - 請求項7において、前記ベントホールは、前記キャビティ側部から最も離隔した縦面に設けられていることを特徴とする金型。
- 請求項1ないし8のいずれか1項に記載の金型を用いた樹脂発泡成形品の成形方法。
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN2009801161402A CN102015237B (zh) | 2008-05-30 | 2009-05-20 | 模具和树脂发泡成形品的成形方法 |
US12/992,136 US9180607B2 (en) | 2008-05-30 | 2009-05-20 | Mold and method for molding resin foamed molding |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2008-143027 | 2008-05-30 | ||
JP2008143027A JP5380909B2 (ja) | 2008-05-30 | 2008-05-30 | 金型及び樹脂発泡成形品の成形方法 |
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WO2009145089A1 true WO2009145089A1 (ja) | 2009-12-03 |
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PCT/JP2009/059263 WO2009145089A1 (ja) | 2008-05-30 | 2009-05-20 | 金型及び樹脂発泡成形品の成形方法 |
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US (1) | US9180607B2 (ja) |
JP (1) | JP5380909B2 (ja) |
CN (1) | CN102015237B (ja) |
WO (1) | WO2009145089A1 (ja) |
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JP5951439B2 (ja) * | 2012-10-05 | 2016-07-13 | 東洋ゴム工業株式会社 | シート用バックパッド及びその製造方法 |
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JP6866740B2 (ja) | 2017-04-14 | 2021-04-28 | トヨタ紡織株式会社 | シートクッション材の製造方法及びその製造用発泡型 |
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- 2008-05-30 JP JP2008143027A patent/JP5380909B2/ja not_active Expired - Fee Related
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2009
- 2009-05-20 CN CN2009801161402A patent/CN102015237B/zh active Active
- 2009-05-20 WO PCT/JP2009/059263 patent/WO2009145089A1/ja active Application Filing
- 2009-05-20 US US12/992,136 patent/US9180607B2/en active Active
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JPH04312811A (ja) * | 1991-04-11 | 1992-11-04 | Toyota Motor Corp | 表皮一体発泡成形方法 |
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JP5380909B2 (ja) | 2014-01-08 |
CN102015237B (zh) | 2013-10-09 |
US20110062614A1 (en) | 2011-03-17 |
CN102015237A (zh) | 2011-04-13 |
US9180607B2 (en) | 2015-11-10 |
JP2009286054A (ja) | 2009-12-10 |
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